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KN INSTALLATION AND OPERATION INSTRUCTIONS
Annual start-up
The boiler and system must be inspected, started
and serviced at least annually by a qualified service
technician. Follow all procedures specified in
the
K N
manuals. Failure to inspect, test and
maintain the boiler and system could result
in severe personal injury, death or substantial
property damage.
Electrical shock hazard
— Use caution
when working on the boiler where electrical
components are exposed. Turn off power to the
boiler if necessary to avoid potential for electrical
shock.
Annual start-up overview
Perform start-up, pages 32 – 40
Perform the complete start-up, testing and inspection procedures
given on pages 32 through 40 to ensure the boiler and system
comply with the requirements in this manual.
In addition, perform the additional follow-up procedures given
below.
Perform follow-up procedures
Operating conditions or abuse can damage the boiler or system
components. The start-up checklist that follows includes
inspections and testing intended to verify that the boiler and
system are still fully functional.
Annual start-up checklist
❑
Discuss system performance with the
homeowner or boiler operator
• Ask the homeowner or boiler operator to rate the performance
of the heating system over the last season.
• If the homeowner or boiler operator identifies boiler or
system problems, identify the cause and adjust or repair as
necessary.
❑
Inspect the air filter
• Remove, inspect (and clean if needed) the air filter. (See
instructions in the Maintenance section.)
If the filter enclosure and blower inlet show signs
of drywall dust, construction debris or other
deposits, you may need to inspect the burner.
Follow the procedure in the Maintenance
section. Accumulation of debris in the burner can
result in burner damage and potential for severe
personal injury, death or substantial property
damage.
If the burner is removed for inspection, also
inspect the boiler heat exchanger. If the heat
exchanger is damaged or blocked with debris,
consult the factory for corrective action.
Operating the boiler with a damaged or
13
obstructed heat exchanger could result in severe
personal injury, death or substantial property
damage.
❑
Verify boiler water treatment
• If the system requires water treatment, make sure the treat-
ment is being performed as required. Ensure that the water
softener, if used, is operational and is being maintained.
• If the system uses antifreeze, check the antifreeze concentra-
tion and inhibitor level. If the levels are low, check for leaks or
other causes. Adjust the antifreeze level or refill the system as
indicated.
❑
Check expansion tank & air vents
• Inspect the relief valve and piping to be sure there are no
signs of relief valve leakage.
• If the relief valve has been weeping, make sure the expansion
tank is not waterlogged or undersized.
• When performing the boiler start-up, watch the pressure
gauge as the boiler and system heat up. If the pressure rises
too fast or too high, the relief valve is not working properly.
Correct the problem as required.
• Make sure all air vents are operating correctly.
❑
Inspect and test the relief valve
• Follow the instructions on the relief valve label to inspect
and test the boiler relief valve.
When discharging the relief valve, make sure
there is not risk of spraying water to you or
others.
❑
Condensate line maintenance
• Make sure the condensate line, condensate pump and
neutralization system, if used, are operational.
• Remove the condensate line at the boiler hose barb
connection.
• Pour water into the line and make sure the water drains
freely. Flush or replace the line if necessary.
• Fill the condensate trap by attaching a 3/8 inch clear plastic
tube to the hose barb. Pour water into the tubing until the
trap is full.
• Remove the clear tubing and reattach the condensate line to
the boiler hose barb.
❑
Perform a complete start-up
• Inspect, adjust and start-up the boiler and system components
as instructed on pages 32 through 40. Perform all procedures
to ensure the boiler and system are operating properly.
❑
Review with homeowner/operator
• Review the User’s information manual with the homeowner
or operator.
• Make sure that all maintenance procedures are being
followed and that all instructions are clear and understood.