2
Maintenance
Service Manual
32
Review with owner
1. Review the Knight Boiler User’s Information Manual
with the owner.
2. Emphasize the need to perform the maintenance
schedule specified in the Knight Boiler User’s
Information Manual (and in this manual as well).
3. Remind the owner of the need to call a licensed
contractor should the boiler or system exhibit any
unusual behavior.
4. Remind the owner to follow the proper shutdown
procedure and to schedule an annual start-up at the
beginning of the next heating season.
Cleaning boiler heat exchanger
For recommended materials; including brush, appropriate
extension(s), refractory cover, and detailed instructions see
Table 2-2 - Heat Exchanger Cleaning Kits.
1. Shut
down
boiler:
• Follow the “To Turn Off Gas to Appliance”
instructions for the boiler in Section 10 - Startup of
the Installation and Operation Manual.
• Do not drain the boiler unless it will be exposed to
freezing temperatures. If using freeze prevention
fluid in system, do not drain.
2. Allow time for the boiler to cool to room temperature
if it has been firing.
3. Remove the nuts securing the heat exchanger access
cover to the heat exchanger and set aside.
4. Remove the heat exchanger access cover, burner, and
gas/air arm assembly.
Oiled bearing circulators
1. The circulator shipped with the Knight boiler is water-
lubricated. No oiling is required.
2. Check other circulators in the system. Oil any circulators
requiring oil, following circulator manufacturer’s
instructions. Over-oiling will damage the circulator.
3. Replace the boiler front access cover.
The boiler contains ceramic fiber
materials. Use care when handling
these materials per the instructions on
page 3 of this manual. Failure to comply
could result in severe personal injury.
WARNING
9. Allow the heat exchanger to thoroughly dry.
10. Remove the field supplied rear refractory cover from the
back of the combustion chamber of the heat exchanger and
reassemble.
11. Close isolation valves on piping to isolate boiler from
system. Attach a hose to the boiler drain and flush boiler
thoroughly with clean water by using purging valves to
allow water to flow through the water make-up line to the
boiler.
12. Perform start-up and check-out procedures in the Check
Flame and Combustion - Section 10 - Startup of the
Installation and Operation Manual.
13. Replace the access cover and restore boiler to operation.
Table 2-2 Heat Exchanger Cleaning Kits
Model
Kit
Number
Part
Number
Component
Description
81
-
106
KIT30062
CTN20005
Rear Refractory Cover
MSC20083* Nylon 4" Wheel Brush*
MSC20085 1/4" x 12" Drill Extension
151
-
286
KIT30063
CTN20005
Rear Refractory Cover
MSC20083* Nylon 4" Wheel Brush*
MSC20084
3mm Allen Wrench
MSC20086 1/4" x 24" Drill Extension
* Do NOT use a metal brush. Only use
the kit provided brush or an equivalent
replacement nylon brush.
CAUTION
NOTICE
Rope gasket is intended for sealing combustion
(FIG. 2-3). If damaged DO NOT reuse, the
heat exchanger door must be replaced. Consult
factory for replacement heat exchanger door
(kit WTR3080).
ROPE GASKET
CAUTION:
I
F GASKET IS DAMAGED
DO NOT
REUSE, THE HEAT EXCHANGER DOOR
MUST BE REPLACED.
Figure 2-3 Rope Gasket - Heat Exchanger Door
5. Remove the condensate hose from the heat exchanger
end. Connect a field supplied 3/4” diameter hose to
a drain pan. Using field supplied means, cover the
refractory in the back of the combustion chamber of the
heat exchanger.
6. Use a vacuum cleaner to remove any accumulation on
the boiler heating surfaces. Do not use any solvent.
7. Brush the heat exchanger while dry using a nylon
bristle brush.
Caution:
DO NOT use a metal brush.
Re-vacuum the heat exchanger.
8. Finish cleaning using a clean cloth dampened with
warm water. Rinse out debris with a low pressure water
supply.
