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Knight 151 Service Manual

Outdoor boiler
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OKB-SER Rev A
Outdoor Knight
Boiler
Service Manual
Models: 151 - 286
This manual must only be used
WARNING
by a qualified heating installer
/ service technician. Read all
instructions, including this
manual and the Outdoor
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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Summary of Contents for Knight 151

  • Page 1 OKB-SER Rev A Outdoor Knight Boiler Service Manual Models: 151 - 286 This manual must only be used WARNING by a qualified heating installer / service technician. Read all instructions, including this manual and the Outdoor Knight Boiler Installation and Operation Manual, before installing.

  • Page 2: Table Of Contents

    Contents 2. MAINTENANCE CONTENTS ................ 2 Maintenance and Annual Startup ........ 28-32 Hazard Definitions .............. 2 3. TROUBLESHOOTING PLEASE READ BEFORE PROCEEDING ......3 Before Troubleshooting ............ 33 Handling Ceramic Fiber Materials ........3 Check Control Module Fuses .......... 33 When servicing boiler ...........

  • Page 3: Please Read Before Proceeding

    User – This manual is for use only by Outdoor Knight Boiler Installation and a qualified heating installer/service Operation Manual). technician. Refer to the Outdoor Knight Any claims for damage or shortage Boiler User’s Information Manual for in shipment must be filed immediately your reference.

  • Page 4: When Servicing Boiler

    Outdoor Knight 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 install the appliance where it will be exposed to freezing temperatures.

  • Page 5: What Is In This Manual

    Outdoor Knight Boiler Service Manual What is in this manual? Service Maintenance Near boiler piping • Service and maintenance schedules • Address reported problems • Typical system components • Inspect boiler area and boiler interior The Outdoor Knight boiler display •...

  • Page 6: Service Near Boiler Piping

    This piping reference is included to specify the Near Boiler Piping specific to the outdoor boiler. This piping scheme is important for proper operation of the SMART SYSTEM control. See the Outdoor Knight Boiler Installation and Operation Manual for more detailed piping diagrams.

  • Page 7: The Outdoor Boiler Display

    Outdoor Knight Boiler Service Manual Service Service (continued) The Outdoor Knight boiler display NAVIGATION DIAL (PRESS OR TURN) 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):...

  • Page 8: Control Inputs

    Outdoor Knight Boiler 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...

  • Page 9: Control Outputs

    Outdoor Knight Boiler Service Manual Service Service (continued) Control outputs ALARM BELL LOW VOLTAGE 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

    Outdoor Knight Boiler Service Manual Service Service General Operation Access modes How the boiler operates User The user can adjust space heating and tank target temperatures The outdoor 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 Outdoor Knight Boiler 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 Outdoor Knight Boiler 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.

  • Page 13: Display Panel Menu Access

    Outdoor Knight Boiler 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].

  • Page 14: Display Panel Parameter Access

    Outdoor Knight Boiler 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

    Outdoor Knight Boiler 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)
  • Page 16 Outdoor Knight Boiler 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...
  • Page 17 Outdoor Knight Boiler 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...
  • Page 18 Outdoor Knight Boiler 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...

  • Page 19: Viewable And Changeable Control Parameters

    Outdoor Knight Boiler 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.

  • Page 20: Temperature Settings

    Outdoor Knight Boiler Service Manual Service To save any changes and return to the Home Screen, press the SH1 - SH3 Differential Set Point RIGHT SELECT [HOME] key. To return to the Status Screen The SH Differential sets how many degrees below the offset...
  • Page 21 Outdoor Knight Boiler Service Manual Service (continued) Freeze Protection Burner On SH/DHW Switching Time When a boiler has a space heating demand and it receives a If running the pumps does not prevent the inlet temperature DHW demand, it will immediately switch to the DHW demand from falling closer to freezing, the SMART SYSTEM control and start a timer.

  • Page 22: Outdoor Reset

    Outdoor Knight Boiler Service Manual Service Outdoor Reset This parameter can be changed by the installer by accessing the Outdoor (1-3) High parameters. The temperature range is In accordance with the United States Energy Policy and low outdoor air temperature set point to 104°F (40°C). The Conservation Act, this boiler is equipped with outdoor default value is 70°F (21°C).
  • Page 23 Outdoor Knight Boiler 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,...
  • Page 24 Outdoor Knight Boiler Service Manual Service Ramp Settings BMS Thermostat Input When controlling the boiler through the 0 - 10V BMS input or Please note that the brackets ([]) denote NOTICE through ModBus, the boiler can be enabled one of two ways.

  • Page 25: Circulation Pumps

    Outdoor Knight Boiler 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 Outdoor Knight Boiler 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.
  • Page 27 Outdoor Knight Boiler 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...

  • Page 28: Maintenance

    Outdoor Knight Boiler Service Manual Maintenance Maintenance and annual startup Table 2-1 Service and Maintenance Schedules Owner maintenance Service technician (see the Outdoor Knight User’s Information Manual (see the following pages for instructions) for 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 Outdoor 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 3 - Hydronic Piping of the Outdoor Knight inoperative. Shut down the boiler until a Boiler Installation and Operation Manual for suggested new relief valve has been installed.

  • Page 31: Check Burner Flame

    1. Start boiler and perform checks and tests specified condition, and ground continuity is satisfactory, replace in Section 7 - Start-up of the Outdoor Knight Boiler the flame sense electrode. Installation and Operation Manual.

  • Page 32: Review With Owner

    9. Allow the heat exchanger to thoroughly dry. 10. Remove the field supplied rear refractory cover from the 1. Review the Outdoor Knight Boiler User’s Information back of the combustion chamber of the heat exchanger and Manual with the owner.

  • Page 33: Troubleshooting

    Outdoor Knight Boiler Service Manual Troubleshooting Check control module fuses Label all wires prior to disconnection WARNING when servicing controls. Wiring errors can cause improper and ALWAYS check control module fuses before NOTICE dangerous operation. Always replacing control module or any major disconnect power to the boiler components (blower, etc.).

  • Page 34: Corrective Action

    Outdoor Knight Boiler 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 Outdoor Knight Boiler Installation and Operation Manual for correct terminal location.
  • Page 36 - Supply gas problem. Natural gas pressures should be between 4 inches w.c. and • Refer to Section 4 - Gas Connections of the Outdoor Knight 14 inches w.c. LP gas pressures should Boiler Installation and Operation Manual for detailed...
  • Page 37 • Refer to Section 4 - Gas Connections of the Outdoor high gas pressure switch tripped. Knight Boiler Installation and Operation Manual for (will require a manual detailed information concerning the gas supply.
  • Page 38 4 - 14 inches w.c. and display to reset.) LP gas pressures should be between 8 - 14 inches w.c. Refer to Section 4 - Gas Connections of the Outdoor Knight Boiler Installation and Operation Manual for detailed information concerning the gas supply.
  • Page 39 Outdoor Knight Boiler 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 • Adjust the set point of the auto reset limit to a higher setting up to a maximum of 200°F. Reference the Outdoor Knight 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.
  • Page 41 Outdoor Knight Boiler Service Manual Troubleshooting (continued) Table 3-4 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION • 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.
  • Page 42 Outdoor Knight Boiler 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.
  • Page 43 Outdoor Knight Boiler 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 • Verify that the boiler pump is set to the proper speed or that the pump is the proper size. Reference Section 3 - Hydronic Piping of the Outdoor Knight 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.
  • Page 45 • Verify that the boiler pump is set to the proper speed or that the boiler pump is the proper size. Reference Outlet Temp Section 3 - Hydronic Piping of the Outdoor Knight Boiler High Outlet water temperature has exceeded the...

  • Page 46: Combustion Analysis Procedure

    Outdoor Knight Boiler 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...

  • Page 47: Gas Valve Adjustment Procedure

    • Check for obstructions at the vent/air intake terminals. or Obstruction • Refer to Section 4 - Gas Connections of the Outdoor Knight Boiler Installation and Operation Gas Supply Pressure Manual for the proper gas supply for the outdoor boiler.

  • Page 48: Revision Notes

    Revision Notes: Revision A (ECO #C11234) initial release. OKB-SER Rev A 10/12...

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