Lochinvar Knight 80 285 User Manual

KB-USER-05  
User’s Information Manual  
Models: 80 - 285  
Starting Serial #H07H10040039  
ƽ WARNING  
If the information in this manual is not followed exactly, a fire or  
explosion may result causing property damage, personal injury or  
loss of life.  
This appliance MUST NOT be installed in any location where  
gasoline or flammable vapors are likely to be present.  
WHAT TO DO IF YOU SMELL GAS  
• Do not try to light any appliance.  
• Do not touch any electric switch; do not use any phone in your  
building.  
• Immediately call your gas supplier from a near by phone.  
Follow the gas supplier’s instructions.  
• If you cannot reach your gas supplier, call the fire department.  
• Installation and service must be performed by a qualified  
installer, service agency, or the gas supplier.  
Save this manual for future reference.  
User’s Information Manual  
Please read before proceeding  
The Knight Boiler Installation and  
NOTICE  
Boiler service and maintenance –  
Operation Manual along with the Knight  
To avoid electric shock, disconnect electrical supply  
before performing maintenance.  
Boiler Service Manual are for use only by  
a
qualified heating installer/service  
technician. Refer only to this User’s  
Information Manual for your reference.  
Improper installation, adjustment,  
alteration, service or maintenance can  
cause property damage, personal injury  
(exposure to hazardous materials) or loss  
of life. Installation and service must be  
performed by a qualified installer, service  
agency or the gas supplier (who must  
read and follow the supplied instruction  
before installing, servicing, or removing  
this boiler. This boiler contains materials  
that have been identified as carcinogenic,  
or possibly carcinogenic, to humans).  
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. This boiler is equipped with a control which  
will automatically shut down the boiler should air or  
vent be blocked. If vent or air blockage is easily  
accessible and removable, remove it. The boiler should  
attempt to restart. If blockage is not obvious or cannot  
be removed, have the boiler and system checked by a  
qualified service technician.  
• Should overheating occur or gas supply fail to shut off,  
do not turn off or disconnect electrical supply to the  
circulator. Instead, shut off the gas supply at a location  
external to the appliance.  
When calling or writing about the boiler –  
Please have the boiler model and serial  
number from the boiler rating plate.  
NOTICE  
Consider piping and installation when  
determining boiler location.  
• Do not use this boiler if any part has been under water.  
The possible damage to a flooded appliance can be  
extensive and present numerous safety hazards. Any  
appliance that has been under water must be replaced.  
Any claims for damage or shortage in  
shipment must be filed immediately  
against the transportation company by  
the consignee.  
Boiler water –  
Thoroughly flush the system (without boiler  
connected) to remove sediment. The high-efficiency  
heat exchanger can be damaged by build-up or  
corrosion due to sediment.  
Factory warranty (shipped with unit)  
does not apply to units improperly  
installed or improperly operated.  
Failure to adhere to the guidelines on this  
page can result in severe personal injury,  
death, or substantial property damage.  
ƽ WARNING  
• Do not use petroleum-based cleaning or sealing  
compounds in the boiler system. Gaskets and seals in  
the system may be damaged. This can result in  
substantial property damage.  
• Do not use “homemade cures” or “boiler patent  
medicines. Serious damage to the boiler, personnel,  
and/or property may result.  
• Continual fresh make-up water will reduce boiler life.  
Mineral buildup in the heat exchanger reduces heat  
transfer, overheats the stainless steel heat exchanger,  
and causes failure. Addition of oxygen carried in by  
makeup water can cause internal corrosion. Leaks in  
boiler or piping must be repaired at once to prevent  
makeup water.  
Freeze protection fluids –  
• NEVER use automotive antifreeze. Use only inhibited  
propylene glycol solutions, which are specifically  
formulated for hydronic systems. Ethylene glycol is  
toxic and can attack gaskets and seals used in hydronic  
systems.  
3
User’s Information Manual  
1 Prevent combustion air contamination  
If the boiler combustion air inlet is located  
in any area likely to cause contamination,  
or if products which would contaminate  
the air cannot be removed, you must have  
the combustion air and vent re-piped and  
Table 1 Corrosive Contaminants and Sources  
ƽ WARNING  
Products to avoid:  
Spray cans containing chloro/fluorocarbons  
Permanent wave solutions  
terminated  
to  
another  
location.  
Contaminated combustion air will  
damage the boiler, resulting in possible  
severe personal injury, death, or  
substantial property damage.  
Chlorinated waxes/cleaners  
Chlorine-based swimming pool chemicals  
Calcium chloride used for thawing  
Sodium chloride used for water softening  
Refrigerant leaks  
If the boiler combustion air inlet is  
located in a laundry room or pool facility,  
for example, these areas will always  
contain hazardous contaminants.  
ƽ WARNING  
Paint or varnish removers  
Pool and laundry products and common household and  
hobby products often contain fluorine or chlorine  
compounds. When these chemicals pass through the boiler,  
they can form strong acids. The acid can eat through the  
boiler wall, causing serious damage and presenting a possible  
threat of flue gas spillage or boiler water leakage into the  
building.  
Hydrochloric acid/muriatic acid  
Cements and glues  
Antistatic fabric softeners used in clothes dryers  
Chlorine-type bleaches, detergents, and cleaning solvents  
found in household laundry rooms  
Adhesives used to fasten building products and other  
similar products  
Please read the information listed in Table 1.  
If  
contaminating chemicals will be present near the location of  
the boiler combustion air inlet, have your installer pipe the  
boiler combustion air and vent to another location, per the  
Knight Boiler Installation and Operation Manual.  
Areas likely to have contaminants  
Dry cleaning/laundry areas and establishments  
Swimming pools  
To prevent the potential of severe personal  
ƽ WARNING  
Metal fabrication plants  
injury or death, check for areas and  
Beauty shops  
products listed in Table 1 before installing  
the boiler or air inlet piping.  
Refrigeration repair shops  
Photo processing plants  
If contaminants are found, you MUST:  
• Remove contaminants permanently.  
—OR—  
Auto body shops  
• Relocate air inlet and vent  
terminations to other areas.  
Plastic manufacturing plants  
Furniture refinishing areas and establishments  
New building construction  
Remodeling areas  
Garages with workshops  
4
User’s Information Manual  
2 Maintenance schedule  
Owner maintenance  
Service technician  
(see pages 6 - 8 for detailed instructions)  
(see the Knight Boiler Service Manual)  
• Check boiler area  
General:  
• Reported problems  
• Check pressure/temperature  
gauge  
• Inspect interior; clean and vacuum if  
necessary  
Daily  
• Clean condensate trap and fill with fresh  
water  
Check for leaks (water, gas, flue,  
condensate)  
• Verify flue and air lines in good condition  
and sealed tight  
• Check vent piping  
• Check air piping  
Check system water pressure/system  
piping/expansion tank  
• Check control settings  
Monthly  
• Check air and vent termination  
• Ignition and flame sense electrodes  
(sand off any deposits; clean and  
reposition)  
screens  
• Check relief valve  
• Wiring and connections  
• Check condensate drain system  
• Check automatic air vents  
• Perform  
start-up  
checkout  
and  
performance verification per Section 10  
in the Knight Installation and Operation  
Manual.  
• Flame inspection (stable, uniform)  
• Flame signal (at least 4 mA)  
Test low water cutoff (if used)  
Periodically  
•Clean the heat exchanger if flue  
temperature is more than 54°F above  
return water temperature.  
• Reset button (low water cutoff)  
• Check boiler piping (gas and  
water) for leaks  
If combustion or performance  
indicate need:  
Every  
6 months  
• Operate relief valve  
• Clean heat exchanger  
• Remove and clean burner using  
compressed air only  
• Clean the blower wheel  
End  
of season  
months  
•Shut boiler down (unless boiler  
used for domestic hot water)  
Follow the maintenance procedures given throughout this manual. Failure to perform the service and  
maintenance or follow the directions in this manual could result in damage to the boiler or system,  
resulting in severe personal injury, death, or substantial property damage.  
ƽ WARNING  
5
User’s Information Manual  
2 Maintenance schedule  
Maintenance procedures  
Read the list of potential materials listed in Table 1 on  
page 4 of this manual. If any of these products are in the  
room from which the boiler takes its combustion air, they  
must be removed immediately or the boiler combustion  
air (and vent termination) must be relocated to another  
area.  
Boiler must be serviced and maintained  
The boiler must be inspected and started  
ƽ WARNING  
annually at the beginning of the heating  
season by a qualified service technician. In  
addition, the maintenance and care of the  
boiler designated on page 5 of this manual  
and explained on pages 6 through 8 must  
be performed to assure maximum boiler  
efficiency and reliability. Failure to service  
and maintain the boiler and system could  
result in equipment failure, causing  
possible severe personal injury, death, or  
substantial property damage.  
Check pressure/temperature gauge  
1. Make sure the pressure reading on the boiler pressure/  
temperature gauge does not exceed 24 psi. Higher  
pressure may indicate a problem with the expansion  
tank.  
2. Contact a qualified service technician if problem persists.  
Check vent piping  
1. Visually inspect the flue gas vent piping for any signs of  
blockage, leakage, or deterioration of the piping. Notify  
your qualified service technician at once if you find any  
problems.  
The following information provides  
NOTICE  
detailed instructions for completing the  
maintenance items listed in the  
maintenance schedule on page 5. In  
addition to this maintenance, the boiler  
must be serviced and started up at the  
beginning of each heating season by a  
qualified service technician.  
Failure to inspect the vent system as noted  
ƽ WARNING  
above and have it repaired by a qualified  
service technician can result in vent system  
failure, causing severe personal injury or  
death.  
Check boiler area  
Check air piping  
To prevent potential of severe personal  
ƽ WARNING  
injury, death, or substantial property  
1. Visually inspect the air inlet termination to be sure it is  
unobstructed. Inspect the entire length of air piping to  
ensure piping is intact and all joints are properly sealed.  
damage, eliminate all materials discussed  
below from the boiler vicinity and the  
vicinity of the boiler combustion air inlet.  
If contaminants are found:  
2. Call your qualified service technician if you notice any  
problems.  
Remove products immediately from the  
area. If they have been there for an  
extended period, call a qualified service  
technician to inspect the boiler for possible  
damage from acid corrosion.  
Check relief valve  
1. Inspect the boiler relief valve and the relief valve  
discharge pipe for signs of weeping or leakage.  
If products cannot be removed,  
2. If the relief valve often weeps, the expansion tank may  
not be working properly. Immediately contact your  
qualified service technician to inspect the boiler and  
system.  
immediately call  
a
qualified service  
technician to re-pipe vent and air piping  
and locate vent termination/air intake  
away from contaminated areas.  
Check condensate drain system  
1. Combustible/flammable materials -- Do not store  
combustible materials, gasoline or any other flammable  
vapors or liquids near the boiler. Remove immediately if  
found.  
1. Inspect the condensate drain line, condensate PVC  
fittings and condensate trap.  
Fill condensate trap with water  
2. Air contaminants -- Products containing chlorine or  
fluorine, if allowed to contaminate the boiler intake air,  
will cause acidic condensate in the boiler. This will cause  
significant damage to the boiler if allowed to continue.  
1. Remove the PVC cap retaining screw from the PVC cap  
(FIG. 1).  
2. Remove the 2" PVC cap with the switch located at the top  
of the trap (FIG. 1).  
6
User’s Information Manual  
2 Maintenance schedule  
(continued)  
3. Fill with fresh water until the water begins to pour out of  
the drain.  
Use materials approved by the authority  
having jurisdiction. In the absence of  
other authority, PVC and CPVC pipe must  
comply with ASTM D1785 or D2845.  
Cement and primer must comply with  
ASME D2564 or F493. For Canada use  
CSA or ULC certified PVC or CPVC pipe,  
fittings, and cement.  
NOTICE  
4. Replace the cap. Press the cap onto the trap until the cap  
makes contact with the drain.  
5. Replace the retaining screw.  
The condensate trap (FIG. 1) must be filled  
ƽ WARNING  
with water during all times of boiler  
operation to avoid flue gas emission from  
the condensate drain line. Failure to fill the  
trap could result in severe personal injury  
or death.  
To allow for proper drainage on large  
horizontal runs, a second line vent may be  
required and tubing size may need to  
increase to 1 inch.  
NOTICE  
The condensate line must remain  
unobstructed, allowing free flow of  
condensate. If condensate is allowed to  
freeze in the line or if the line is obstructed  
in any other manner, condensate can exit  
from the boiler tee, resulting in potential  
water damage to property. Call your  
qualified service technician to inspect  
the boiler and system.  
Figure 1 Condensate Trap  
8. A condensate removal pump is required if the boiler is  
below the drain. When installing a condensate pump,  
select one approved for use with condensing boilers and  
furnaces. The pump should have an overflow switch to  
prevent property damage from condensate spillage. Call  
your qualified service technician to inspect  
the boiler and system.  
Condensate disposal  
Figure 2 Condensate Disposal  
1. This boiler is a high efficiency appliance that produces  
condensate.  
2. The side of the boiler has a 1/2 inch PVC union for  
connection of a 1/2 inch PVC pipe (FIG. 2).  
3. Slope condensate tubing down and away from the boiler  
into a drain or condensate neutralizing filter. Condensate  
from the Knight boiler will be slightly acidic (typically  
with a pH from 3 to 5). Install a neutralizing filter if  
required by local codes. Call your qualified service  
technician to inspect the boiler and system.  
A
Neutralizer Kit is available from the factory  
(Kit #4004). Call your qualified service technician to  
install.  
4. Install the 1/2 inch PVC tee assembly (shipped with the  
unit) as shown in FIG. 2. Call your qualified service  
technician to inspect the boiler and system.  
5. Leave the top of the 1/2 inch tee OPEN. This is needed as  
a vacuum break.  
6. Do not expose condensate line to freezing temperatures.  
7. Use only plastic tubing or piping as a condensate drain  
line (FIG. 2).  
7
User’s Information Manual  
2 Maintenance schedule  
Have leaks fixed at once by a qualified  
service technician. Failure to comply could  
result in severe personal injury, death, or  
substantial property damage.  
Check automatic air vents  
ƽ WARNING  
1. Reference FIG. 3 below.  
2. Remove the caps (FIG. 3 – A) from the automatic air  
vents in the system and check operation by slightly  
depressing valve “B” (FIG. 3) with the tip of a  
screwdriver.  
3. Replace the front access door.  
Operate relief valve  
1. Before proceeding, verify that the relief valve outlet has  
been piped to a safe place of discharge, avoiding any  
possibility of scalding from hot water.  
3. If the air vent valve appears to be working freely and not  
leaking, replace cap A”, twisting the cap all the way on.  
4. Loosen cap A” one turn to allow vent to operate.  
To avoid water damage or scalding due to  
ƽ WARNING  
valve operation, a metal discharge line  
5. Have the automatic air vent(s) replaced if it does not  
operate correctly.  
must be connected to the relief valve outlet  
and run to a safe place of disposal. This  
discharge line must be installed by a  
qualified heating installer or service  
technician in accordance with the  
instructions in the Knight Boiler  
Installation and Operation Manual. The  
discharge line must be terminated so as to  
eliminate possibility of severe burns or  
property damage should the valve  
discharge.  
Figure 3 Automatic Air Vent  
2. Read the boiler pressure/temperature gauge to make  
sure the system is pressurized. Lift the relief valve  
top lever slightly, allowing water to relieve through  
the valve and discharge piping.  
3. If water flows freely, release the lever and allow the valve  
to seat. Watch the end of the relief valve discharge pipe  
to ensure that the valve does not weep after the line has  
had time to drain. If the valve weeps, lift the seat again to  
attempt to clean the valve seat. If the valve continues to  
weep afterwards, contact your qualified service  
technician to inspect the valve and system.  
Test low water cutoff (if installed)  
1. If the system is equipped with a low water cutoff, test the  
low water cutoff periodically during the heating season,  
following the low water cutoff manufacturer’s  
instructions.  
4. If water does not flow from the valve when you lift the  
lever completely, the valve or discharge line may be  
blocked. Immediately shut down the boiler, following  
the operating instructions on page 9 of this manual. Call  
your qualified service technician to inspect the boiler and  
system.  
Reset button (low water cutoff)  
1. Testing the low water cutoff shuts the unit off. Press the  
RESET button on the low water cutoff to turn the unit  
back on.  
Check boiler piping (gas and water)  
Shut boiler down (unless boiler is used  
for Domestic Water)  
1. Remove the boiler front access door and perform a gas  
leak inspection per steps 1 through 7 of the Operating  
Instructions on page 9. If gas odor or leak is detected,  
immediately shut down the boiler following the  
procedures on page 9. Call a qualified service technician.  
1. Follow To Turn Off Gas to Appliance” on page 9 of this  
manual.  
2. Do not drain the system unless exposure to freezing  
temperatures will occur.  
2. Visually inspect for leaks around water piping.  
Also inspect the circulators, relief valve, and fittings.  
Immediately call a qualified service technician to repair  
any leaks.  
3. Do not drain the system if it is filled with an antifreeze  
solution.  
4. DO NOT shut down boilers used for domestic water  
heating, they must operate year-round.  
8
User’s Information Manual  
3 Operating instructions  
9
User’s Information Manual  
4 SMART SYSTEM control module  
Knight boiler control module  
Use the control panel (FIG. 4) to set temperatures, operating conditions, and monitor boiler operation.  
Figure 4 Control Panel  
10  
User’s Information Manual  
4 SMART SYSTEM control module  
Access modes  
User  
The user can adjust space heating target temperature by using  
the UP and DOWN buttons (FIG. 4) at any time during  
normal operation. By entering the USER code (0704), the  
user can also change temperature units, time and date, and  
night setback settings. In User Mode, the following  
parameters can be viewed but not changed:  
• Boiler outlet water target temperature in DHW  
Mode  
• Boiler model number  
• Software version  
Total operating hours  
Total cycles  
Installer  
Most parameters are available only to the installer, accessible  
only by entering the installer access code. Have your qualified  
service technician reference the Knight Boiler Service  
Manual.  
Saving parameters (reference parameter table on  
page 12 of this manual)  
To save parameters and exit programming:  
Press the ENTER/RESET button (FIG. 4).  
To keep parameter settings only for a current operating  
cycle:  
Press the MENU/EXIT button (FIG. 4) 3 times after making  
all desired parameter changes.  
To enter a parameter and continue programming:  
Press the MENU/EXIT button 1 time to return to the  
parameter listings; press again to return to the menu listings.  
Remember to press the ENTER/RESET button when finished  
programming in order to save the changes made.  
Have your qualified service technician reference the Knight  
Boiler Service Manual for a detailed description of  
parameters and access modes.  
11  
User’s Information Manual  
4 SMART SYSTEM control module  
Parameter table  
USER ACCESS  
INSTALLER ACCESS  
SEE  
PAGE  
MENU SUB ITEM  
DESCRIPTION  
DISPLAY MODIFY DISPLAY MODIFY  
1
2
3
Boiler Model  
14  
14  
14  
14  
14  
14  
14  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
No  
Yes  
Yes  
No  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
No  
Yes  
Yes  
No  
User Code  
Date and Time  
4
Software Version  
Temperature Units  
Night Setback Temperature  
Night Setback Times  
A
5
6
7
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
1
SH Set Point User  
14  
Yes  
Yes  
Yes  
Yes  
B
1
2
Hours Running SH  
Hours Running DHW  
Ignition Attempts  
14  
14  
14  
14  
Yes  
Yes  
Yes  
Yes  
No  
No  
No  
No  
Yes  
Yes  
Yes  
Yes  
No  
No  
No  
No  
C
3
4
Show Last 10 Errors  
1
DHW Boiler Set Point  
15  
15  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
E
2
SH/DHW Switching Time  
5
6
Outdoor Air Shutdown  
15  
15  
15  
15  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Outdoor Air Shutdown  
Differential  
F
8
Boost Temperature  
9
Boost Time  
12  
User’s Information Manual  
4 SMART SYSTEM control module  
(continued)  
Night setback times  
A: General  
If parameter A6 is set to anything other than 32°F, the night  
setback feature becomes active. This will require start and  
stop times to be programmed for the days that reduced  
temperatures are required. These times can be changed by  
the user or the installer by accessing parameter A7. Each day  
of the week (Sunday through Saturday) will have an on and  
off time.  
Boiler model  
The control will display “Knight Boiler” as the model number  
because the same control is used on several models. This will  
be displayed when parameter A1 has been accessed. This  
parameter is not changeable.  
User code  
Example: Monday ON: 22:30, Tuesday OFF: 6:45. If you  
wish to skip a day and have no night setback, leave the on and  
off times the same. The default times for each day will be  
00:00 (midnight).  
The User Code allows the user to access and change a limited  
number of control parameters. The access code can be  
changed by the user or the installer to a code of their  
choosing. To change the code, parameter A2 must be  
accessed. The default code is 0704. The code can be changed  
one digit at a time by using the arrow keys on the display.  
B: Temperature settings  
SH set point user  
Date and time  
The SH set point user sets the water temperature set point for  
fixed operation or the maximum temperature set point when  
the outdoor air sensor is used. This parameter can be  
changed by the user or the installer by accessing parameter  
B1. The temperature range of this parameter is 50°F to 190°F.  
The default value is 125°F.  
The control uses an internal clock for the night setback  
feature and for logging of events. For these features to work  
correctly, the clock must be set when the boiler is first  
installed or anytime the boiler has been powered off for more  
than 30 days. To set the clock, parameter A3 must be  
accessed. The date and time are displayed as “YY:MM:DD W  
hh:mm. YY = year, MM = month, DD = date, W = day (1 =  
Sunday, 2 = Monday, etc.), hh = hour (24 hour time;  
2:00 PM = 14:00), mm = minutes.  
C: Data logging  
Hours running SH  
The internal clock does not adjust for  
NOTICE  
The hours running SH parameter shows the total number of  
hours the boiler has been in the SH firing position. This  
parameter can be viewed by the user and the installer by  
accessing parameter C1.  
Daylight Savings Time and therefore,  
will require a manual adjustment.  
Software version  
The software version allows the user to view the software  
version in use by the control. This software controls the  
operation of the boiler. When a new software version  
becomes available, the existing control can be replaced with a  
new control to update the software.  
Hours running DHW  
The hours running DHW parameter shows the total number  
of hours the boiler has been in the DHW firing position. This  
parameter can be viewed by the user and the installer by  
accessing parameter C2.  
Temperature units  
Ignition attempts  
The control can be configured to display temperature in  
either °C or °F. This parameter can be changed by the user or  
the installer by accessing parameter A5. The default is °F.  
The ignition attempts parameter shows the total number of  
times the boiler has attempted to fire. This parameter can be  
viewed by the user and the installer by accessing parameter  
C3.  
Night setback temperature  
Once the internal clock has been set correctly, the night  
setback feature can be used to program a lower water  
temperature set point for space heating. This parameter can  
be changed by the user or the installer by accessing parameter  
A6. The temperature range for this parameter is 32°F to  
140°F. The feature is turned off with a setting of 32°F. The  
default value is 32°F.  
Show last 10 errors  
The control will log the 10 most current errors with the date  
and time the error occurred. This parameter can be viewed  
by the user and the installer by accessing parameter C4.  
13  
User’s Information Manual  
4 SMART SYSTEM control module  
Boost temperature  
E: DHW settings  
If a SH demand lasts longer than the programmed time delay  
setting and there have been no DHW demands, the control  
will increase the water temperature set point by the amount  
in this parameter. If the SH demand continues through  
another time period, the set point will be increased again.  
This will continue until either the SH demand ends, a  
maximum of 20 increases has occurred, or the maximum set  
point has been reached. Once the SH demand has been  
satisfied the set point will revert back to its calculated setting.  
The boost temperature can be changed by the installer by  
accessing parameter F8. The temperature range of this  
parameter is 0°F to 45°F. The default value is 0°F. This feature  
will be active if this parameter is set to anything other than  
F.  
DHW boiler set point  
When a DHW call for heat becomes active, the control will  
use the DHW boiler set point to determine the firing rate of  
the boiler based on the actual water temperature. This  
parameter can be changed by the installer by accessing  
parameter E1. The temperature range of this parameter is  
50°F to 190°F. The default value is 180°F.  
SH/DHW switching time  
The SH/DHW switching time parameter sets the length of  
time the control will stay in DHW Mode when a SH call has  
been received. After this time period has expired the control  
will revert to SH Mode. If a DHW call is still active the timer  
will reset. After the time period has expired the control will  
revert back to DHW Mode. This will continue until one of  
the demands has been satisfied. This parameter can be  
changed by the installer by accessing parameter E2. The time  
range of this parameter is 10 minutes to 240 minutes. The  
default value is 30 minutes.  
Boost time  
The boost time parameter sets the amount of time that must  
elapse with a SH demand before the water temperature set  
point will be increased. This parameter can be changed by the  
installer by accessing parameter F9. The time range for this  
parameter is 1 minute to 60 minutes. The default value is 20  
minutes.  
F: Outdoor air reset  
Outdoor air shutdown  
When the outdoor air shutdown rises above this point, the  
control will block all SH demands (DHW demands will still  
be active). This parameter can be changed by the user or the  
installer by accessing parameter F5. The temperature range of  
this parameter is 0°F to 120°F. The default value is 80°F.  
Outdoor air shutdown differential  
The outdoor air shutdown differential parameter is the  
number of degrees below parameter F5 the outdoor air  
temperature must go before the boiler will respond to a SH  
demand. This parameter can be changed by the user or the  
installer by accessing parameter F6. The temperature range of  
this parameter is 0°F to 90°F. The default value is 10°F.  
14  
User’s Information Manual  
4 SMART SYSTEM control module  
(continued)  
Status Display Screens  
By using the Previous/Next (, ) arrow keys on the SMART SYSTEM display panel, you can navigate through the eight (8)  
display screens. Each screen will contain two (2) viewable items. The following is a description of the individual items and  
what they can display:  
Screen  
Display shows:  
Description  
The unit has been turned OFF by the Enter/Reset button on the  
SMART SYSTEM display panel.  
BLR: OFF  
The unit has not received a call for heat from a remote thermostat  
nor has it received a call for heat from a DHW thermostat.  
Standby  
The unit has met the water temperature set point, but is still  
receiving a call for heat from either a remote thermostat or a DHW  
thermostat.  
Set Point Met  
Prepurge  
The unit has initiated a 10 second purge period on a call for heat.  
The unit has begun a 5 second spark period to ignite the main  
burner.  
Ignition  
SH***% Rate  
The unit has fired and is running at the displayed percentage.  
#1  
The call for heat has been satisfied and the unit runs the fan for an  
additional 10 seconds to clear the combustion chamber and vent  
system of residual flue products.  
Postpurge  
Service  
The unit has been placed in a temporary mode that will allow the  
unit to fire at 100% of rate for the purpose of combustion analysis.  
When the outlet sensor has been selected as the control sensor  
(default), the control will display the outlet temperature as well as  
the set point in parenthesis.  
OUT: ***.*F(***)  
***.*F  
If the outlet sensor has not been selected as the control sensor, only  
the outlet temperature will be displayed.  
Open  
The control does not detect the outlet sensor.  
Shorted  
The outlet sensor wires or the sensor itself has become shorted.  
Press the Next arrow key on the SMART SYSTEM display to access Screen #2.  
If the inlet sensor has not been selected as the control sensor, only  
the inlet temperature will be displayed.  
IN: ***.*F  
When the inlet sensor has been selected as the control sensor, the  
control will display the inlet temperature as well as the set point in  
parenthesis.  
***.*F (***)  
#2  
Open  
The control does not detect the inlet sensor.  
Shorted  
The inlet sensor wires or the sensor itself has become shorted.  
The difference between the inlet temperature and the outlet  
temperature.  
RISE: ***.*F  
Press the Next arrow key on the SMART SYSTEM display to access Screen #3.  
15  
User’s Information Manual  
4 SMART SYSTEM control module  
Status Display Screens (cont’d)  
By using the Previous/Next (, ) arrow keys on the SMART SYSTEM display panel, you can navigate through the eight (8)  
display screens. Each screen will contain two (2) viewable items. The following is a description of the individual items and  
what they can display:  
Screen  
Display shows:  
Description  
If the system supply sensor has not been selected as the control  
sensor, only the system temperature will be displayed.  
SYS: ***.*F  
When the system supply sensor has been selected as the control  
sensor, the control will display the system temperature as well as the  
set point in parenthesis.  
***.*F (***)  
Open  
The control does not detect the system supply sensor.  
The system supply sensor wires or the sensor itself has become  
shorted.  
#3  
Shorted  
The control will display the outdoor air temperature as sensed by the  
outdoor air sensor.  
OUTDOOR: ***.*F  
Open  
The control does not detect the outdoor air sensor.  
Shorted  
The outdoor air sensor wires or the sensor itself has become shorted.  
Press the Next arrow key on the SMART SYSTEM display to access Screen #4.  
FLUE: ***.*F  
Open  
The control will display the flue temperature.  
The control does not detect the flue sensor.  
Shorted  
The flue sensor wires or the sensor itself has become shorted.  
The control will display the temperature.  
#4  
AUX: ***.*F  
Open  
The control does not detect the auxiliary sensor.  
Shorted  
The auxiliary sensor wires or the sensor itself has become shorted.  
Press the Next arrow key on the SMART SYSTEM display to access Screen #5.  
FAN SPD: ****RPM  
FLAME SIG: **.*uA  
The control will display the actual fan motor RPM.  
#5  
#6  
The control will display the flame signal in dc microamps.  
Press the Next arrow key on the SMART SYSTEM display to access Screen #6.  
The control has not received a call for heat from a remote  
thermostat.  
SH CFH: OFF  
ON  
The control has received a call for heat from a remote thermostat.  
The control has not received a call for heat from a SH remote  
thermostat.  
DHW CFH: OFF  
ON  
The control has received a call for heat from a DHW thermostat.  
Press the Next arrow key on the SMART SYSTEM display to access Screen #7.  
16  
User’s Information Manual  
4 SMART SYSTEM control module  
(continued)  
Status Display Screens (cont’d)  
By using the Previous/Next (, ) arrow keys on the SMART SYSTEM display panel, you can navigate through the eight (8)  
display screens. Each screen will contain two (2) viewable items. The following is a description of the individual items and  
what they can display:  
Screen  
Display shows:  
Description  
The control has not received a DHW call for heat and has not  
powered the DHW pump.  
DHW PUMP: OFF  
The control has received a DHW call for heat and has powered the  
DHW pump.  
ON  
#7  
The DHW call for heat has been satisfied and the DHW pump is  
running for a fixed time to remove any residual heat.  
Delay  
The control will display a 0-10Vdc signal received from a Building  
Management System (BMS) connected to the unit.  
0-10V IN: **.Vdc  
Press the Next arrow key on the SMART SYSTEM display to access Screen #8.  
The control has not received a call for heat from a remote thermostat  
and has not powered the system pump.  
SYS PUMP: OFF  
ON  
The control has received a call for heat from a remote thermostat  
and has powered the system pump.  
The system call for heat has been satisfied and the system pump is  
running for a fixed time to remove any residual heat.  
Delay  
The control has either not received a call for heat from a remote  
thermostat, a remote thermostat is not connected to the unit and the  
water temperature has not dropped below the temperature set point  
of the control to initiate a call for heat, or the control has received a  
DHW call for heat from a DHW thermostat.  
BLR PUMP: OFF  
#8  
The control has received a call for heat from a remote thermostat or  
a remote thermostat is not connected and the water temperature has  
dropped below the temperature set point of the control to initiate a  
call for heat.  
ON  
The call for heat has been satisfied and the boiler pump is running  
for a fixed time to remove any residual heat.  
Delay  
Press the Next arrow key on the SMART SYSTEM display to access Screen #9.  
17  
User’s Information Manual  
4 SMART SYSTEM control module  
Status Display Screens (cont’d)  
Operation of the cascade  
The boiler designated as the Leader will have two additional display screens that can be viewed. These screens will provide  
information regarding the operation of the Cascade. Each screen will contain two viewable items. The following is a  
description of the individual items and what they can display:  
Screen  
Display shows:  
Description  
The Leader control has been turned off by the Enter/Reset button on  
the Smart System display.  
Cas: Off  
The Leader boiler has not received a call for heat from a remote  
thermostat.  
Cas: Standby  
The Cascade is now active. The system supply temperature will be  
displayed. The Cascade set point will be displayed in parenthesis.  
Cas: 127.4F (130)  
The Cascade has met the water temperature set point, but is still  
receiving a call for heat from a remote thermostat.  
Cas: Setpoint Met  
Cas: No Members  
Cas: S6 Not Present  
PMP: Off  
The Leader control could not detect any Member controls to  
participate in the Cascade.  
#9  
The system supply sensor is not connected to the Leader boiler.  
The Leader control has not received a call for heat from a remote  
thermostat and has not powered the system pump.  
The Leader control has received a call for heat from a remote  
thermostat and has powered the system pump.  
PMP: On  
The system call for heat has been satisfied and the system pump is  
running for a fixed time to remove any residual heat.  
PMP: Delay  
Press the Next arrow key on the SMART SYSTEM display to access Screen #10.  
The first percentage shows the firing rate that is being sent to the last  
Cas Pow: ***% ***%  
boiler called on. The second percentage shows the total power  
available to the Cascade.  
Shows the number of boilers connected to the Cascade. The Leader  
is designated as 0. Members will be designated 1 - 7. If a “-“ is used  
in place of a number, that boiler is either not connected, or in a  
lockout mode and not available for the Cascade. If a “d” is used in  
place of a number, that boiler is handling a DHW demand and is not  
available for the Cascade. If the number is flashing, then that boiler  
is providing heat to the Cascade. As the lead boiler is changed from  
day to day, that boiler’s address will be shown first in the string of  
numbers. In the example, boilers 0 - 3 are present, boiler 2 is the lead  
boiler, and boiler 0 is heating an indirect DHW tank.  
Present: 01234567  
#10  
Example:  
Present: 23----d1  
Press the Next arrow key on the SMART SYSTEM display to roll back to Screen #1. At any point if you wish to access an  
earlier screen, press the Previous arrow key on the SMART SYSTEM display.  
18  
User’s Information Manual  
Notes  
Revision Notes: Revision 3 (KB-USER-03) reflects  
the addition of the Dungs information to the manual.  
Revision 4 (ECO #C02545) reflects changes made  
to the “Check Air Piping” section on page 6 along  
with the removal of Models 399 - 500 and the  
addition of references to periodic cleaning of screens  
in vent terminations.  
Revision 5 (ECO #C02940) reflects changing 0° to  
32°F under the Night Setback Times section on page  
13.  
KB-USER-05  
1/09  

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