Installation & Operation Manual
67
12
Maintenance
(continued)
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, 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.
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.
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.
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.
Check all piping for leaks
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.
WARNING
WARNING
WARNING
WARNING
WARNING
Figure 12-1
Condensate Trap
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.
Failure to inspect for the above conditions
and have them repaired can result in severe
personal injury or death.
WARNING
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.
