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9 Maintenance (continued)
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.
The boiler contains ceramic fiber
materials. Use care when handling these
materials per instructions in the Service
Manual. Failure to comply could result in
severe personal injury.
ƽ WARNING
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.
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.
9. Allow the heat exchanger to thoroughly dry.
10. Remove the fi eld 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 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.
12. Perform start-up and check-out procedures in the Check
Flame and Combustion - Section 7 - Startup on pages 35
and 37 of this manual.
13. Replace the access cover and restore boiler to operation.
Table 9B Heat Exchanger Cleaning Kits
Model
Kit
Number
Part
Number
Component
Description
400 KIT30063
CTN20005 Rear Refractory Cover
MSC20083* Nylon 4" Wheel Brush*
MSC20084 3mm Allen Wrench
MSC20086 1/4" x 24" Drill Extension
501 - 801 KIT30064
CTN20005 Rear Refractory Cover
MSC20083* Nylon 4" Wheel Brush*
MSC20085 1/4" x 12" Drill Extension
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.
ƽ CAUTION
NOTICE
Rope gasket is intended for sealing combustion
(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).
ROPE GASKET
CAUTION: IF GASKET IS DAMAGED
DO NOT REUSE, THE HEAT EXCHANGER DOOR
MUST BE REPLACED.
Figure 9-5 Rope Gasket - Heat Exchanger Door
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.
Outdoor Knight XL Installation & Operation Manual