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.
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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
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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.
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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
0°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.
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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.
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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.
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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.
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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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