Installation & Operation Manual
12 Maintenance
WARNING
WARNING
WARNING
Follow the Service and maintenance procedures given throughout this manual and in component literature shipped with the boiler. Failure to perform the service and maintenance could result in damage to the boiler or system. Failure to follow the directions in this manual and component literature could result in severe personal injury, death, or substantial property damage.
The boiler should be inspected annually only by a qualified service technician. In addition, the maintenance and care of the boiler designated in Table 12A and explained on the following pages must be performed to assure maximum boiler efficiency and reliability. Failure to service and maintain the boiler and system could result in equipment failure.
Electrical shock hazard – Turn off power to the boiler before any service operation on the boiler except as noted otherwise in this instruction manual. Failure to turn off electrical power could result in electrical shock, causing severe personal injury or death.
Address reported problems
1.Inspect any problems reported by the owner and correct before proceeding.
Inspect boiler area
1. Verify that boiler area is free of any combustible materials, |
WARNING The condensate trap must be filled 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.
Check all piping for leaks
gasoline and other flammable vapors and liquids. |
2. Verify that air intake area is free of any of the contaminants |
listed in Section 1 of this manual. If any of these are |
present in the boiler intake air vicinity, they must be |
removed. If they cannot be removed, reinstall the air and |
vent lines per this manual and the Knight Wall Mount |
Service Manual. |
WARNING
Eliminate all system or boiler leaks. Continual fresh makeup water will reduce boiler life. Minerals can build up in sections, reducing heat transfer, overheating heat exchanger, and causing heat exchanger failure. Leaking water may also cause severe property damage.
Inspect boiler interior
1.Remove the front access cover and inspect the interior of the boiler.
2.Vacuum any sediment from inside the boiler and components. Remove any obstructions.
Clean condensate trap
1.Remove the clean out cap on the bottom of the trap. Let the condensate and any debris drain out.
2.Fill with fresh water until the water begins to pour out of the drain.
3.Replace the clean out cap and resume operation.
Figure 12-1 Condensate Trap
74 
1.Inspect all water and gas piping and verify to be leak free.
2.Look for signs of leaking lines and correct any problems found.
3.Check gas line using the procedure found in Section 7 - Gas Connections.
Flue vent system and air piping
1.Visually inspect the entire flue gas venting system and air piping for blockage, deterioration or leakage. Repair any joints that show signs of leakage. Verify that air inlet pipe is connected and properly sealed.
2.Verify that boiler vent discharge and air intake are clean and free of obstructions.
WARNING Failure to inspect for the above conditions and have them repaired can result in severe
personal injury or death.
Check water system
1.Verify all system components are correctly installed and operational.
2.Check the cold fill pressure for the system. Verify it is correct (must be a minimum of 12 psi).
3.Watch the system pressure as the boiler heats up (during testing) to ensure pressure does not rise too high. Excessive pressure rise indicates expansion tank sizing or performance problem.
4.Inspect automatic air vents and air separators. Remove air vent caps and briefly press push valve to flush vent. Replace caps. Make sure vents do not leak. Replace any leaking vents.