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9
Maintenance
Check fl ame signal
1. At high fi re the fl ame signal shown on the display should
be at least 10 microamps.
2. A lower fl ame signal may indicate a fouled or damaged
fl ame sense electrode. If cleaning the fl ame sense electrode
does not improve, ground wiring is in good condition,
and ground continuity is satisfactory, replace the fl ame
sense electrode.
3. See Section 3 - Troubleshooting in the Outdoor Knight
XL Service Manual for other procedures to deal with low
fl ame signal.
Review with owner
1. Review the Outdoor Knight XL User's Information
Manual with the owner.
2. Emphasize the need to perform the maintenance schedule
specifi ed in the Outdoor Knight XL 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 9B - Heat Exchanger Cleaning Kits.
1. Shut down boiler:
• Follow the "To Turn Off Gas to Appliance" instructions
for the boiler in Section 7 - Startup.
• Do not drain the boiler unless it will be exposed to
freezing temperatures. If using freeze prevention fl uid
in system, do not drain.
2. Allow time for the boiler to cool to ambient temperature
if it has been fi ring.
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.
The boiler contains ceramic fiber
WARNING
materials. Use care when handling these
materials per instructions in the Service
Manual. Failure to comply could result in
severe personal injury.
5. Remove the condensate hose from the heat exchanger
end. Connect a fi eld supplied 3/4" diameter hose to
a drain pan. Using fi eld supplied means, cover the
refractory in the back of the combustion chamber of the
heat exchanger.
(continued)
6. Use a vacuum cleaner to remove any accumulation on the
7. Brush the heat exchanger while dry using a nylon bristle
8. Finish cleaning using a clean cloth dampened with warm
9. Allow the heat exchanger to thoroughly dry.
10. Remove the fi eld supplied rear refractory cover from the
11. Close isolation valves on piping to isolate boiler from
12. Perform start-up and check-out procedures in the Check
13. Replace the access cover and restore boiler to operation.
Table 9B Heat Exchanger Cleaning Kits
Figure 9-5 Rope Gasket - Heat Exchanger Door
Outdoor Knight XL Installation & Operation Manual
boiler heating surfaces. Do not use any solvent.
brush. Caution: DO NOT use a metal brush. Re-vacuum
the heat exchanger.
water. Rinse out debris with a low pressure water supply.
back of the combustion chamber of the heat exchanger and
reassemble.
system. Attach a hose to the boiler drain and fl ush boiler
thoroughly with clean water by using purging valves to
allow water to fl ow through the water make-up line to the
boiler.
Flame and Combustion - Section 7 - Startup on pages 35
and 37 of this manual.
Kit
Part
Model
Number
Number
CTN20005
MSC20083*
400
KIT30063
MSC20084
MSC20086
CTN20005
MSC20083*
501 - 801
KIT30064
MSC20085
MSC20086
* Do NOT use a metal brush. Only use
CAUTION
the kit provided brush or an equivalent
replacement nylon brush.
CAUTION:
IF GASKET IS DAMAGED
DO NOT REUSE, THE HEAT EXCHANGER DOOR
MUST BE REPLACED.
Rope gasket is intended for sealing combustion
NOTICE
(FIG. 9-5). If damaged DO NOT reuse, the
heat exchanger door must be replaced. Consult
factory for replacement heat exchanger door
(kit WTR3080 and WTR3086).
Component
Description
Rear Refractory Cover
Nylon 4" Wheel Brush*
3mm Allen Wrench
1/4" x 24" Drill Extension
Rear Refractory Cover
Nylon 4" Wheel Brush*
1/4" x 12" Drill Extension
1/4" x 24" Drill Extension
ROPE GASKET
53
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