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KBXII-SER Rev C
Service Manual
Models: 400 - 801
This manual must only be used
WARNING
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 ................................ 28-32 Hazard Definitions .............................................................. 2 3. TROUBLESHOOTING PLEASE READ BEFORE PROCEEDING ........................ 3 Before Troubleshooting .................................................... 33 Handling Ceramic Fiber Materials ...................................... 3 Check C
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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 – Please have the boiler model and serial XL 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 i
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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 o
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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 op
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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. DOMESTIC HOT WATER PUMP DIRT SEPARATOR INDIRECT SYSTEM SENSOR DOMESTIC HOT WATER SYSTEM PUMP TANK Y-STRAINER (RECOMMENDED) BOILER PUMP TO FLOOR
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Service Manual 1 Service (continued) The Knight XL 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 SETPOINTS = NAVIGATION Dial - Pressing Down SHDN = Right SELECT Key 7
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Service Manual 1 1 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 / HI-LIMIT SENSOR FLUE GAS SENSOR AIR PRESSURE SWITCH LOUVER PROVING SWITCH FLAME SENSOR BLOCKED DRAIN SWITCH SMART CONTROL
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Service Manual 1 1 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 9
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Service Manual 1 1 Service Service Access modes General Operation How the boiler operates User The user can adjust space heating and tank target temperatures The Knight XL 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. The date and time, and fully condensing operation. The blower pulls in gas and air the temperature un
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Service Manual 1 1 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). The flow switch and/or LWCO must close. 3. The control turns on power to the louver relay. The louver proving switch, air pressure switch,
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Service Manual 1 1 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. If programmed for normal DHW operation (not as a zone), the DHW pump will turn on first, then the boiler pump will turn off 2 seconds later. This will divert the boiler’s outlet water from the
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Service Manual 1 1 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. Rotate the NAVIGATION dial clockwise until 5 is displayed (first digit on the left). Press the NAVIGATION dial to s
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Service Manual 1 1 Service Service Display panel parameter access Table 1-3 This is a typical example of accessing 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. Rotate the NAVIGATION dial counterclockwise until the arrow (>) is
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Service Manual 1 1 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 See Menu Description Page Display Modify Display Modify Time and Date 19 Yes Yes Yes Yes Software Version (read only) 19 No No Yes No Temperature Units (ºC/ºF) 19 Yes Yes Yes Yes SH Night Setback Offset 19 No No Yes Yes SH Night Setback On Times 19 No No Yes Yes SH Night Setback Of
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Service Manual 1 1 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 See Menu Description Page Display Modify Display Modify DHW Boiler Set Point 21 No No Yes Yes Tank Set Point 21 Yes Yes Yes Yes Tank Set Point Differential 21 No No Yes Yes DHW Boiler Offset 21 No No Yes Yes DHW Boiler Differential 21 No No Yes Yes SH/DHW Swit
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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 User Access Installer Access See Menu Description Page Display Modify Display Modify Boost Temperature 23 No No Yes Yes Boost Time 23 No No Yes Yes Anti-Cycling Time 23 No No Yes Yes Anti-Cycling Override Differential 23 No No Yes Yes Ramp Delay 23 No No Yes Yes Ramp Settings 24 No No Yes
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Service Manual 1 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 See Menu Description Page Display Modify Display Modify BMS Type 26 No No Yes Yes Volts at Min 26 No No Yes Yes Volts at Max 26 No No Yes Yes Rate at Min Volts 26 No No Yes Yes Rate at Max Volts 26 No No Yes Yes Set Point at Min Volts 27 No No Yes Yes Set Point at Max Vol
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Service Manual 1 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 active. There are 7 start times and 7 stop times each for the General space heating and DHW night setback features. Both m
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Service Manual 1 Service Rotate the NAVIGATION dial to select the trigger you wish SH1 - SH3 Differential Set Point to skip and press the NAVIGATION dial. “SK” will appear The SH differential sets how many degrees below the offset next to that trigger. You can rotate the NAVIGATION dial the temperature has to drop before the boiler turns back again to select another trigger if you wish. If you wish to on. This parameter can only be changed by the install
