Service Manual
2Maintenance (continued)
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
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, 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 the Knight XL Installation and Operation 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 XL Installation and Operation Manual.
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
Figure 2-1 Condensate Trap
RETAINING
SCREW
2” PVC CAP WITH
BLOCKED DRAIN SWITCH
PVC TEE ASSEMBLY (FACTORY SUPPLIED)
CONDENSATE FROM
HEAT EXCHANGER 
TO FLOOR
DRAIN
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
1. | Inspect the condensate drain line, condensate PVC |
| fittings, and condensate trap. |
2. | Remove the PVC cap retaining screw from the PVC cap |
| (FIG. |
3. | Remove the 2 inch PVC cap with the switch located at the |
| top of the trap (FIG. |
4. | Remove any sediment in the trap. |
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.
5. | Fill with fresh water until the water begins to pour out of |
| the drain. |
6. | Replace the cap. Press the cap onto the trap until the cap |
| makes contact with the drain. |
7. | Replace the retaining screw. |
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 of the Knight XL Installation and Operation Manual.
29 
