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KBX-SER Rev E
Service Manual
Models: 399 - 800
This manual must only be
WARNING
used by a qualified heating
installer / service technician.
Read all instructions,
including this manual and the
Knight XL 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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Contents 2. MAINTENANCE CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Maintenance and Annual Startup . . . . . . . . . . . . . . . . . . 23-27 Hazard Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 3. TROUBLESHOOTING PLEASE READ BEFORE PROCEEDING . . . . . . . . . . . . 3 Before Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Handling Ceramic Fiber Materials . . . . . . . . . . . . . . . . . . . 3 Check Con
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Service Manual Please read before proceeding Installer – Read all instructions, When calling or writing about the boiler – WARNING NOTICE including this manual and the Knight XL Please have the boiler model and serial Installation and Operation Manual, number from the boiler rating plate. before installing. Perform steps in the Consider piping and installation when order given. determining boiler location (see the Knight User – This manual is for use only by a XL Installation and Operation Ma
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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 extern
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Service Manual What is in this manual? Service Maintenance � Service and maintenance schedules Near boiler piping � Address reported problems � Typical system components � Inspect boiler area and boiler interior � Clean condensate trap The Knight XL display � Check all piping for leaks � Display panel readout, buttons and their functions � Check air openings � Flue vent system and air piping Control module inputs � Check water system � Control module inputs and options � Check expansion tank � C
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Service Manual 1 Service Near boiler piping This piping reference is included to specify the Near Boiler Piping specific to the Knight XL. This piping scheme is important for proper operation of the SMART SYSTEM control. See the Knight XL Installation and Operation Manual for more detailed piping diagrams. FROM SYSTEM DOMESTIC HOT WATER PUMP SYSTEM PUMP INDIRECT DOMESTIC HOT WATER TO TANK SYSTEM BOILER PUMP TO FLOOR DRAIN 6 FROM R TO
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Service Manual 1 Service (continued) The Knight XL display � Press to turn boiler off or • Hold 5 seconds to enter code back on Input Mode (Menu Mode) SHUTDOWN � Press to select a menu item � Press to move up one level � Press after parameter programming in Menu Mode or to exit to store parameter data Menu Mode � Press to exit Service Mode ENTER / RESET MENU / EXIT DISPLAY SCREEN SERVICE BUTTON PC CONNECTION PORT UP DOWN PREVIOUS NEXT � Press to toggle display during normal � Press t
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Service Manual 1 1 Ser Service vice Control inputs GAS PRESSURE SWITCH (OPTIONAL) DHW THERMOSTAT (OPTIONAL) ROOM THERMOSTAT / ZONE CONTROL LOW VOLTAGE FLOW SWITCH CONNECTION BOARD SYSTEM SENSOR DHW TANK SENSOR (OPTIONAL) OUTDOOR SENSOR (OPTIONAL) SEQUENCER / BUILDING MANAGEMENT SYSTEM (OPTIONAL) LOW WATER CUTOFF (OPTIONAL) SMART CONTROL INLET TEMPERATURE MODULE SENSOR OUTLET TEMPERATURE SENSOR FLUE GAS SENSOR AIR PRESSURE SWITCH HIGH LIMIT FLAME SENSOR BLOCKED DRAIN SWITCH DISPLAY PANEL PC I
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Service Manual 1 1 Ser Service vice (continued) Control outputs ALARM BELL AUX. DEVICE RELAY LOW VOLTAGE CONNECTION BOARD RUN TIME CONTACTS SEQUENCER / BUILDING MANAGEMENT SYSTEM BOILER PUMP SYSTEM PUMP DHW PUMP IGNITOR BLOWER SMART CONTROL MODULE GAS VALVE DISPLAY PANEL PC INTERFACE 9
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Service Manual 1 1 Ser Service vice General Operation Access modes How the boiler operates User The Knight XL uses an advanced stainless steel heat exchanger and an electronic control module that allows fully condensing The user can adjust space heating set point using the UP and operation. The blower pulls in gas and air and pushes flue DOWN buttons at any time during normal operation. By products out of the boiler through the heat exchanger and entering the USER code (0704), the user can
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Service Manual 1 1 Ser Service vice (continued) Sequence of operation Table 1A Sequence of operation - space heating and DHW OPERATION DISPLAY BLR: Standby 1. Upon a call for heat, the control turns on the appropriate pumps (system and boiler pumps for space heating call; DHW pump OUT: 123.8F(129) for DHW call). 2. The control connects 120 VAC to the blower. The blower does not run at this time. BLR: Standby • The manual reset high limit must be closed and reset. • Once the pumps are turne
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Service Manual 1 1 Ser Service vice Sequence of operation (continued) Table 1A (continued from previous page) Sequence of operation - space heating and DHW OPERATION DISPLAY 8. If the boiler is not part of a cascade, and the DHW call for heat remains active for more than 30 minutes, and the space heating call for heat is also active, then the control will turn on the boiler BLR: SH 41% RATE pump, turn off the DHW pump after 2 seconds, and resume modulating based on the space heating set
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Service Manual 1 1 Ser Service vice (continued) Display panel menu access Table 1B Use this procedure to access menus from the display panel BUTTON COMMENTS OPERATION DISPLAY Boiler turns off (this ensures BLR:OFF ENTER/RES Press 1 time in normal operation OUT:127.3ºF uninterrupted programming) Enter Menu Code: Digit shown underlined at left will MENU/EXIT Hold for 5 seconds -- display will change 0000 flashing flash Press 9 times to change last digit Enter Menu Code: Digit shown underlined at
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Service Manual 1 1 Ser Service vice Display panel parameter access Table 1C This is a typical example of accessing a parameter, shown for parameter I2, boiler pump delay OPERATION BUTTON DISPLAY COMMENTS This example shows how to access parameter I2, boiler pump delay. The first display shown is at the beginning of the menu listings, after entering the installer acess code. >A General The caret symbol, “>” highlights Beginning of menu listings B Temp Settings the selectable line >A General
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Service Manual 1 1 Ser Service vice (continued) Parameter table Table 1D This table lists SMART SYSTEM control module parameters and where to access them USER ACCESS INSTALLER ACCESS SEE MENU SUB ITEM DESCRIPTION PAGE DISPLAY MODIFY DISPLAY MODIFY 1 Boiler Model 17 Yes No Yes No 2 User Code 17 Yes Yes Yes Yes 3 Date and Time 17 Yes Yes Yes Yes 4 Software Version 17 Yes No Yes No A 5 Temperature Units 17 Yes Yes Yes Yes 6 Night Setback Temperature 17 Yes Yes Yes Yes 7 Night Setback Times 17 Yes
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Service Manual 1 1 Ser Service vice Parameter table (continued) Table 1D (continued from previous page) This table lists SMART SYSTEM control module parameters and where to access them USER ACCESS INSTALLER ACCESS SEE MENU SUB ITEM DESCRIPTION PAGE DISPLAY MODIFY DISPLAY MODIFY 1 Anti-cycling Time 20 No No Yes Yes Return Temperature Differential 2 20 No No Yes Yes G for Ending Anti-Cycling 3 Ramp Delay On/Off 20 No No Yes Yes SH Controlling Sensor 1 21 No No Yes Yes (Outlet/System, Inlet) SH
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Service Manual 1 Service Viewable and changeable control parameters Before changing parameters, note the Night setback times CAUTION settings so that the unit can be returned to its If parameter A6 is set to anything other than 32°F (0°C), the original operating parameters. night setback feature becomes active. This will require start and stop times to be programmed for the days that reduced A: General temperatures are required. These times can be changed by the Boiler model user or the insta
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Service Manual 1 Service SH Differential E: DHW settings The SH differential sets how many degrees below the turn off DHW boiler set point temperature the temperature has to go before the boiler will turn When a DHW call for heat becomes active, the control will use on. This parameter can only be changed by the installer by the DHW boiler set point to determine the firing rate of the accessing parameter B5. The temperature range of this boiler based on the actual water temperature. This par
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Service Manual 1 1 Ser Service vice (continued) Figure 1-1 Outdoor Air Reset Curve WATER TEMPERATURE SET POINT MAXIMUM RESET Default = 180°F USER SET POINT Default = 125°F MINIMUM RESET Default = 70°F Default = 70°F Default = 25°F OUTDOOR OUTDOOR AIR AT MINIMUM RESET TEMPERATURE OUTDOOR AIR AT MAXIMUM RESET Outdoor air shutdown Maximum air temperature When the outdoor air temperature rises to or above this When the outdoor temperature rises above this point, the point, the water temperature wi
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Service Manual 1 1 Ser Service vice Boost temperature G: Anti-cycling If a SH demand lasts longer than the programmed time delay Anti-cycling time setting (F9) and there have been no DHW demands, the control will increase the water temperature set point by the Once a SH demand has been satisfied, a set amount of time amount in this parameter. If the SH demand continues must elapse before the control will respond to a new SH through another time period, the set point will be increased demand.
