Summary of the content on the page No. 1
KBXII-SER Rev B
Service Manual
Models: 400 - 801
WARNING
This manual must only be 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.
Summary of the content on the page No. 2
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 Con
Summary of the content on the page No. 3
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
Summary of the content on the page No. 4
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
Summary of the content on the page No. 5
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
Summary of the content on the page No. 6
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 INDIRECT DIRT SEPARATOR DOMESTIC SYSTEM SENSOR HOT WATER SYSTEM PUMP TANK Y-STRAINER (RECOMMENDED) BOILER PUMP TO FLOOR DRAIN 6 TO FROM SYSTEM SYSTEM FRO
Summary of the content on the page No. 7
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
Summary of the content on the page No. 8
Service Manual 1 1 Ser Service vice 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 BUILDING MANAGEMENT SYSTEM LOW WATER CUTOFF INLET TEMPERATURE SENSOR OUTLET TEMPERATURE / HI-LIMIT SENSOR FLUE GAS SENSOR AIR PRESSURE SWITCH LOUVER PROVING SWITCH FLAME SENSOR BLOCKED DRAIN SWITCH SMART CONTROL MODULE DISPLAY PANEL PC INTERFACE 8
Summary of the content on the page No. 9
Service Manual 1 1 Ser Service vice (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
Summary of the content on the page No. 10
Service Manual 1 1 Ser Service vice Access modes General Operation User How the boiler operates The user can adjust space heating and tank target The Knight XL uses an advanced stainless steel heat temperatures by pressing the NAVIGATION dial when exchanger and an electronic control module that allows “SETPOINTS” is flashing at the bottom of the display. The fully condensing operation. The blower pulls in gas and air date and time, and the temperature units can also be changed. and pushes
Summary of the content on the page No. 11
Service Manual 1 1 Ser Service vice (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, and blocked drain switch must close.
Summary of the content on the page No. 12
Service Manual 1 1 Ser Service vice 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 heating system and send it to the t
Summary of the content on the page No. 13
Service Manual 1 1 Ser Service vice (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 select the next digit. Rotate the NA
Summary of the content on the page No. 14
Service Manual 1 1 Ser Service vice 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 next to TEMPERATURE SETTINGS. Pre
Summary of the content on the page No. 15
Service Manual 1 1 Ser Service vice (continued) Parameter table Table 1-4 This table lists SMART SYSTEM control module parameters and where to access them User Access Installer Access Sub See Menu Description Item Page Display Modify Display Modify 1 Date and Time 19 Yes Yes Yes Yes 2 Software Version (read only) 19 No No Yes No 3 Temperature Units (ºC/ºF) 19 Yes Yes Yes Yes 4 SH Night Setback Offset 19 No No Yes Yes 5 SH Night Setback On Times 19 No No Yes Yes A 6 SH Night Setback Off Times 1
Summary of the content on the page No. 16
Service Manual 1 1 Ser Service vice 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 Sub See Menu Description Item Page Display Modify Display Modify 1 DHW Boiler Set Point 21 No No Yes Yes 2 DHW Tank Set Point 21 Yes Yes Yes Yes 3 Tank Set Point Differential 21 No No Yes Yes 4 Boiler Set Point Offset 21 No No Yes Yes 5 Boiler Set Point Differential 21 No No Yes Yes E 6 SH/DH
Summary of the content on the page No. 17
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 Sub See Menu Description Item Page Display Modify Display Modify 18 Boost Temperature 23 No No Yes Yes F 19 Boost Time 23 No No Yes Yes 1 Anti-Cycling Time 23 No No Yes Yes 2 Anti-Cycling Override Differential 23 No No Yes Yes G 3 Ramp Delay (Enable, Disable) 23 No No Yes Yes 4 SH Ramp Delay 2
Summary of the content on the page No. 18
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 Sub See Menu Description Item Page Display Modify Display Modify 1 BMS Type (Power / Set Point) 26 No No Yes Yes 2 Volts at Min 26 No No Yes Yes 3 Volts at Max 26 No No Yes Yes 4 Rate at Min Volts 26 No No Yes Yes 5 Rate at Max Volts 26 No No Yes Yes J 6 Set Point at Min Volts 27 No No Yes Yes 7 Set Point
Summary of the content on the page No. 19
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 A: General space heating and DHW night setback features. Both may be set Date and Time to any ti
Summary of the content on the page No. 20
Service Manual 1 Service Display Timeout C: Data Logging This is the time in which the display remains illuminated. Reset last 10 errors The range is 10 seconds to 10 minutes. The default is 3 The reset last 10 errors function clears the last 10 errors log. minutes. D: Functions B: Temperature Settings Service Mode Delay Space Heating (SH1, SH2, SH3) Set Point By pressing the pin button on the front of the display for five Mixing valves are required for the CAUTION (5) seconds, the control w
