kn series gas boiler installation & operating instructions
Contents
1. page 12 General Piping Requirements page 13 Heating System Piping page 13 Domestic Water Supply Piping page 16 Condensate page 17 Gas Supply page 17 Electrical WINING uuu l u uu L ua Su page 18 Boiler Op ration unupa rene titres page 18 Operating Instructions page 19 Sequence of Operation page 21 Checking amp Adjustment page 22 DIAGNOSTICS usines inerte page 23 Maintenance venue page 24 Troubleshooting page 25 R pait Parts ciiin eror erede page 26 rao pages 29 32 BEFORE YOU START This manual covers the application installation operation and maintenance of a KN series boiler To obtain the safe dependable efficient operation and long life for which this boiler was designed these instructions must be read understood and followed The KN boiler series has been design certified by CSA for use with natural and propane gas under the latest revision of ANSI Z21 13 CSA 4 9 Gas Fired Low Pressure Steam and Hot Water Boilers and CAN1 3 1 Industrial and Commercial Gas Fired Packaged Boilers Each unit has been constructed and hydrostatical2. OF RUN TO ALLOW FOR CONDENSATE DRAINAGE HIOM S REV 1 Figure 6 Vertical Positive Pressure Venting 10 FT 3 1m MINIMUM TO WALL OR ADJOINING APPROVED BUILDING NORESTRICTIVE TERMINAL MAXIMUM SNOW ROOF ur ME FLASHING N MINIMUM d Jj HIOM 6 REV 1 re PER VENT MANUFACTURER S INSTRUCTIONS EXHAUST la a UL CERTIFIED VENT SYSTEM KN INSTALLATION AND OPERATION INSTRUCTIONS VERTICAL VENT NEGATIVE PRESSURE CATEGORY II The KN is listed as a Category II appliance when vented vertically into a listed metal chimney system Figure 7 The chimney system must provide a negative pressure of 0 02 to 0 15 in 0 57 to 3 81 mm W C at the boiler flue collar with the unit running NOTE When using a listed metal chimney system the chimney system manufacturer s instructions must be followed Multiple KN s can be vented into a single vertical chimney system Refer to HydroTherm KN 10 Venting page 7 Consult factory for multiple KN 6 and KN 20 venting applications When more than one appliance is connected to the same chimney system the system must be large enough to safely vent the combined output of all of the appliances Table 7 lists the equivalent breeching and chimney sizes required for a single boiler installation WARNING If an appliance using any type of a mechanical draft system operating under positive pressure is connected to a chimney flue never connect any other
3. Pump Gate Valve Check Valve Backflow Prevention Temperature amp Pressure Vacuum Relief Thermometer Expansion Aquastat Device Pressure Relief Valve Valve Tank Relief Valve HIOM 12 REV 1 KN INSTALLATION AND OPERATION INSTRUCTIONS Figure 13 Typical Multiple Boiler with Indirect Storage Tank Piping COLD WATER b MAKE UP D N NIN Pump Gate Valve Check Valve Backflow Prevention Temperature amp Pressure Device Pressure Relief Valve CONDENSATE PIPING The condensate trap provided with the boiler must be attached to the bottom pan and piped to a suitable floor drain or condensate pump GAS SUPPLY PIPING WARNING Check the boiler rating plate to make sure that the boiler is for the type of gas that will be used If it isn t do not connect the boiler to the gas supply Failure to comply with this warning can result in extensive property damage severe personal injury or death The KN comes from the factory ready to be piped to the gas supply If for any reason the boiler is not for the type of gas available at the installation site call your HydroTherm representative to resolve the problem Table 9 should be used to ensure that the gas supply piping is sized properly If more than one appliance is supplied by the same supply pipe the piping must be sized based on the maximum possible demand Do not neglect the pressure drop due to pipe fittings Table 9 should be used in conjunction with Table 10 to ensure th
4. GAS TRAIN LOWER BRACKET 70 1276 2 20 GAS VALVE ORIFICE GASKET 59 1068 1 1 21 MAIN GAS ORIFICE 03 1647 1 MAIN GAS ORIFICE 03 1691 1 22 FREQENCY DRIVE 58 1846 1 1 23 Strut Pipe Clamp 56 5910 1 1 24 CONDENSATE DRAIN ASSY 70 1338 1 1 25 DRAIN MOUNTING BRACKET 03 1650 1 1 26 GAS VALVE 02 1570 1 GAS VALVE 02 1574 1 27 PLASTIC COVER LOWER MOUNTING BRACKET 03 1645 1 28 RUBBER GROMMET 750 in ID 1 625 in OD 57 5427 3 3 29 FRONT JACKET PANEL 03 1603 1 FRONT JACKET PANEL 03 1687 1 30 DRAW ROD NUT 5 8 11 UNC 57 2616 12 12 31 FRONT CASTING SECTION 01 1629 1 1 32 DRAW ROD 5 8 11 44 1125 6 DRAW ROD 44 1127 6 33 BASE BOTTOM TUBING 06 1000 2 BASE BOTTOM TUBING 06 1103 2 34 INTERMEDIATE CASTING SECTION 01 1628 4 INTERMEDIATE CASTING SECTION 01 1628 2 35 FLUE BAFFLE 59 1062 5 36 BOTTOM CASTING COVER 01 1631 1 BOTTOM CASTING COVER 01 1635 1 37 PLASTIC COVER UPPER MOUNTING BRACKET 03 1646 1 1 38 1 CONDUIT END 58 1605 2 2 39 3 SQUARE SOCKET PLUG 56 4586 1 3 40 LEFT SIDE LOWER JACKET PANEL 03 1606 1 LEFT SIDE LOWER JACKET PANEL 03 1702 1 41 1 CONDUIT WIREWAY 20 40 1010 1 1 CONDUIT WIREWAY 20 70 1264 1 Page 28 KN INSTALLATION AND OPERATION INSTRUCTIONS Model Size with Item Quantities Below Item Description Part KN 6 KN 10 KN 20
5. applicable provisions of the local building codes Failure to provide adequate combustion air for this boiler water heater can result in excessive levels of carbon monoxide which can result in severe personal injury or death To operate properly and safely this boiler requires a continuous supply of air for combustion NEVER store objects on or around the boiler CAUTION Combustion air contaminated with fluoro carbons or other halogenated compounds such as cleaning solvents and refrigerants will result in the formation of acids in the combustion chamber These acids will cause premature failure of the boiler voiding the warranty CAUTION If the boiler is operated while the building is under construction it must be protected from wood concrete sheet rock and other types of dust Failure to properly protect the unit from construction dust will damage the unit voiding the warranty Page 3 Page 4 Buildings will require the installation of a fresh air duct or other means of providing make up air if the intake air option isn t used Any building utilizing other gas burning appliances a fireplace wood stove or any type of exhaust fan must be checked for adequate combustion air when all of these devices are in operation at one time Sizing of an outside air duct must be done to meet the requirements of all such devices WARNING Never operate the KN 10 in an environment subjected to a negative pressure unless it is Direct Vent
6. All seams and joints in metal pipes must be joined and sealed in accordance with the vent system manufacturer s instructions When horizontal vent runs exceed 5 ft 1 5m they must be supported at 3 ft 0 98 m intervals with overhead hangers The vent system must be pitched down toward the vent terminal 1 4 in ft 21mm m If any part of a single wall metal vent system passes through an unheated space it must be insulated with insulation rated for 400 F 20 C Horizontal vent systems shall terminate at least 4 ft 1 3 m below 4 ft 1 3 m horizontally from or 1 ft 0 23 m above any door window or gravity air inlet into any building It must not terminate less than 4 ft 1 3 m horizontally from and in no case above or below unless a 4 ft 1 3 m horizontal distance is maintained from electric meters gas meters regulators and relief equipment and not less than 7 ft 2 3 m from any adjacent public walkway The bottom of the vent terminal s shall be located at least 5 ft 1 5 m above the air intake terminal s unless there is a 5 ft 7 5 m distance between them Avoid terminal locations likely to be affected by winds snowdrifts people and pets Protect building materials and vegetation from degradation caused by the flue gases KN INSTALLATION AND OPERATION INSTRUCTIONS Vertical Direct Vent Systems see Figure 3 The vent materials used in positive pressure vent Systems must be certified to UL 1738 for installations in the Unite
7. Secondary Piping SYSTEM RETURN X a MAX 12 ga NOTE Not all system valves may be shown Consult local codes for X additional system components which may be necessary SYSTEM COLD WATER SUPPLY MAKE UP ON NN Roi T gh Backflow Prevention Pressure Thermometer Expansion Aquastat Pressure Pump Gate Valve Check Valve Device Relief Valve Tank Reducing Valve HIOM 10 REV 2 Figure 11 Typical Multiple Boiler Reverse Return Piping NOTE Not all system valves may be shown Consult local codes for additional system components which may be necessary SYSTEM COLD WATER SUPPLY MAKE UP COMME E Backflow Prevention Pressure Expansion Aquastat Pressure Device Relief Valve Thermometer Tank Reducing Valve HIOM 11 REV 2 Pump Gate Valve Page 16 DOMESTIC WATER SUPPLY PIPING CAUTION Proper controls must be used to prevent water supplied for domestic use from exceeding 130 F 54 C or a scald injury will occur When higher water temperatures are required for appliances such as a dishwasher a mixing valve or some other tempering means must be installed Households with small children may require water temperatures less than 120 F 49 C Local codes must be complied with General Piping Requirements The KN boiler can be use in combination with an indirect tank to provide hot water for domestic use Piping and componen
8. Tekmar operating control Refer to the Tekmar literature KN INSTALLATION AND OPERATION INSTRUCTIONS Page 26 Figure 19 Exploded View nma W j SS J DA Hi n NE NO y HIOM 19 KN INSTALLATION AND OPERATION INSTRUCTIONS SERVICE AND REPLACEMENT PARTS LIST Page 27 Model Size with Item Quantities Below Item Description Part KN 6 KN 10 KN 20 1 FILTER BOX WELDMENT 70 1346 1 FILTER BOX WELDMENT 70 1280 1 2 BLOWER TO AIR FILTER GASKET 59 1067 1 1 3 FILTER 59 1057 1 FILTER 59 1069 1 4 FILTER BOX FRONT COVER 03 1622 1 5 FILTER BOX SUPPORT BRACKET 03 1651 1 FILTER BOX SUPPORT BRACKET 03 1700 1 6 POTENTIOMETER ADJ LABEL 42 5213 1 1 7 BOILER TEMPERATURE CONTROL 02 4250 1 1 8 PRESS SW MPL 9300 25 02 4881 1 1 9 ELECTRONICS PANEL 60 5602 1 1 10 CONTROL PCBOARD 02 4249 1 1 11 ILLUMINATED ROCKER SWITCH 58 1536 1 1 12 CONTROL PANEL OVERLAY 60 5601 1 CONTROL PANEL OVERLAY 60 5612 1 13 SCANNER COOLING PUMP 09 1518 1 1 14 BURNER CONTROLLER 02 4012 1 1 15 30 VA QUICK CONNECT TRANSFOMER 26 3208 1 1 16 FRONT COMPONENT COVER 60 5600 1 1 17 ELECTRONICS MOUNT PAD ASSY 70 1330 1 1 18 STRUT PIPE CLAMP 56 5909 3 STRUT PIPE CLAMP 56 5911 3 19 GAS TRAIN LOWER BRACKET 70 1333 2
9. alimentation lectrique de l appareil 4 Cet appareil est muni d un dispositif d allumage qui allume automatiquement la veilleuse Ne tentez pas d allumer la veilleuse manuellement 5 Fermer la vanne manuelle d arr t d alimintation de gaz 6 Attendre cinq 5 minutes pour laisser chapper tout le gaz Reniflez tout autour de l appareil y compris pr s du plancher pour d celer une odeur de gaz Si vous sentez une odeur de gaz ARRETEZ Passez l tape B des instructions de s curit sur la portion sup rieure de cette tiquette S il n y a pas d odeur de gaz passez l tape suivante 7 Ouver la vanne manuelle d arr t d alimintation de gaz 8 Mettez l appareil sous tension 9 R glez le thermostat la temp rature d sir e 10 Si l appareil ne se met pas en marche suivez les instructions intitul es couper l admission de gaz de l appareil et appelez un technicien qualifi ou le fournisseur de gaz TO TURN OFF GAS TO APPLIANCE 1 Set the operating control to its lowest setting 2 Turn off all electric power to the boiler if service is to be performed 3 Close the manual main and pilot gas shut off valves COMMENT COUPER L ADMISSION DE GAZ DE L APAREIL 1 R glez le thermostat la temp rature la plus basse 2 Coupez l alimentation lectrique de l appareil s il faut proc der l entretien 3 Fermer la vanne manuelle d arr t d alimintation de gaz SEQUENCE OF OPERATION NO DEMAND St
10. also conform with CSA C22 1 Canadian Electrical Code Part if installed in Canada Install a separate 120 volt 15 amp circuit for the boiler A properly rated shut off switch should be located at the boiler The boiler must be grounded in accordance with the authority having jurisdiction or if none the latest revision of the National Electrical Code ANSI NFPA 70 Line voltage field wiring of any controls or other devices must use copper conductors with a minimum size of 14 awg Use appropriate wiring materials for units installed outdoors Refer to the wiring diagram supplied with the boiler for proper wiring connections BOILER OPERATION WARNING Before proceeding read and fully understand the instructions contained in this manual Do not attempt to operate this boiler if it has not been installed in accordance with the guidelines set forth in this manual Failure to comply with this warning can result in extensive property damage severe personal injury or death Should overheating occur or the gas supply fail to shut off turn off the manual gas control valve to the appliance Do Not interrupt water flow through the boiler En cas de surchauffe ou si l alimentation en gaz ne s arr te pas fermez manuellement le robinet d arr t de l admission de gaz KN INSTALLATION AND OPERATION INSTRUCTIONS Hydronic Heating Boilers Open the make up water valve and slowly fill the boiler and all of the radiation with water Ensu
11. amp VENTILATION SECTION must be followed The vent System must be sized per Table 6 Table 6 Direct Vent Pipe Size Positive Pressure Model Pipe Diameter Size in mm 600 5 127 1000 6 152 2000 9 229 Horizontal Direct Vent Systems Figures 1 8 2 The vent materials used in positive pressure vent systems must be certified to UL 1738 for installations in the United States ULS636 for installations in Canada The vent terminals listed in Table 5 must also be used Below is a list of some of the manufactures that have systems that meet these requirements Others manufacturers that have UL certified systems may be used KN INSTALLATION AND OPERATION INSTRUCTIONS Heat Fab Inc 38 Hayward Street Greenfield MA 01301 800 772 0739 Z Flex U S Inc 20 Commerce Park North Bedford NH 03110 6911 800 654 5600 Protech Systems Inc 26 Gansevoort Street Albany NY 12202 518 463 7284 Flex L International Inc 6385 Kennedy Road Missis sauga ON Canada L5T 2WA 800 561 1980 The maximum equivalent length for the horizontal vent pipe is 80 ft 79 7 m Each 90 elbow and the vent terminal are equal to 10 ft 3 3 m of straight pipe To maximize the performance of single wall sheet metal vent systems locate 90 elbows as far from the boiler as possible and from one another For best results horizontal vent systems should be as short and straight as possible The vent system must be both gas and water tight
12. below 3 8 mA 42 5780 2 5 6 04 Page 32 KN INSTALLATION AND OPERATION INSTRUCTIONS HydroTherm PUMP CONTROL DRY CONTACT KN 6 amp KN 10 SA MAX FIELD WIRING DIAGRAM OUTDOOR SENSOR Units with Tekmar OPTIONAL Modulating Control TEMPERATURE SENSOR BOILER SUPPLY OR DOMESTIC HOT WATER OPTIONAL BOILER OUTLET SENSOR FACTORY WIRED FACTORY WIRED TEKMAR 4 20 mA SIGNAL THERMOSTAT o OR BOILER START kt se J TEKMAR TERMINAL 08 0 ojojdlo op U BLOCK SEE TABLE 1 12 000000000000 12 11 10 9 8 7 USER LOW FLOW INTRLK GAS sw EP INTERLOCK POWER NOTE TERMINAL BLOCKS TERMINAL BLOCK TERMINAL UNPLUG FOR EASY WIRING 14AWG WIRE MAX LIFT CAP TO ACCESS SCREWS MAIN CIRCUIT BOARD PCB 13 J10 1 e 39IMM3S OWA 021 POWER SERVICE 120V 60 HZ 1 PH FLA 8 0 CONTROL TERMINAL BLOCK wn iz G3HOLMS OVA 021 TEKMAR TEMPERATURE CONTROLLER BTC MPA FIELD CONNECTIONS TO LEGEND TEKMAR TERMINAL BLOCK DESIGNATION FACTORY WIRING 1 12 JUMPER FACTORY INSTALLED CTC TERMINAL 1 HEAT DEMAND o TERMINAL 12 24VAC POWER COMMON c NOTE FOR COMPLETE WIRING ES DETAILS SEE DRAWINGS INDICATORS 2 24 THERMOSTAT OR BOILER START CONTACT 42 5775 1 B 42 5775 2 B 5 TERMINAL 2 HEAT DEMAND TO SUITABLE ke i ALARM POWER SENSORS n y SOURCE ne TEMNAS wor REURED EE 7 9 BOIL O TE
13. detected at any time up to the 7800 locking out the 120V wiring on the ignition transformer must be reversed and the test run again to insure that no flame is detected WARNING Improper wiring of the ignition transformer can result in an explosion causing extensive property damage severe personal injury or death 22 Open both manual main shut off valves and the pilot gas shut off valve 23 Reset the Honeywell 7800 The boiler will start and will run at minimum input rate 24 Observe the burner to ensure that it is not operating in an infrared condition during low fire operation Take a flue gas sample using a calibrated analyzer Use a 2 5mm 3 32 allen wrench to adjust the gas valve to produce a CO the same as high fire 8 9 natural gas and 9 10 L P Figure 14 Make small 10 degree adjustments and wait until the CO readings settle before making further adjustments 25 Rotate the screw clockwise to increase the rate counter clockwise to decrease it 26 Move the slide switch to the auto position The boiler input will rise to its maximum input 27 Allow the boiler to stabilize and adjust the input rate per the CHECKING ADJUSTMENT amp OPERATION section below KN INSTALLATION AND OPERATION INSTRUCTIONS Instructions De Mise En Marche 1 ARRETEZ Lisez les instructions de s curit sur la portion sup rieure de cette tiquette 2 R glez le thermostat la temp rature la plus basse 3 Coupez l
14. of this manual for reference 1 Check the operating controls for proper operation 2 A float type low water cutoff device must be flushed out per the manufacturers instructions The probe on a probe low water cut off must be removed cleaned and inspected at least once a year Ensure that the low water cutoffs operate properly In not replace them 3 The flow switch contacts must be open when water flow is not present 4 The relief valve should not weep or discharge water at normal system pressure If it does contact a qualified service technician to have it inspected NEVER try to clean or repair the relief valve If the valve fails to operate properly have it replaced 5 The aquastat high limit controls the maximum water temperature in the boiler It is adjustable from 130 F 54 C to 215 F 102 C If the water temperature reaches the set temperature before the demand for heat has been met the aquastat high limit should shut the boiler off The water temperature should never exceed the maximum set point of 215 F 102 C The aquastat high limit cannot be repaired If it fails to function properly replace it KN INSTALLATION AND OPERATION INSTRUCTIONS 6 Visually check the pilot and main burner flames to ensure proper operation see Figures 17 amp 18 WARNING If the surface of the burner glows bright orange it indicates infrared operation A yellow floating flame indicate a lack of combustion air If either o
15. system for proper size and horizontal pitch and determine there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition Inspecter de facon visuelle le systeme d vacu ation pour d terminer la grosser et l inclinaison horizontale qui conviennent et s assurer que le syst me est exempt d obstruction d tranglement de fruite de corrosion et autres d faillances qui pourraient pr senter des risques C Insofar as is practical close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building Turn on clothes dryers and any appliance not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhaust so they will operate at maximum speed Do not operate a summer exhaust fan for a boiler installation Close fireplace dampers Dans la mesure du possible fermer toutes les portes et les fen tres du b timent et toutes les portes entre d e KN INSTALLATION AND OPERATION INSTRUCTIONS l espace o les appareils toujours raccord s du syst me d vacuation sont install s et les autres espaces du b timent Mettre en marche les s cheuses tous les appareils non raccord s au Syst me d vacuation commun et tous les ventilateurs d extraction comme les hottes de cuisin re et les ventilateurs des salles de bain S a
16. water or excessive moisture during operation or servicing 3 Ensure that the floor is structurally sound and will support the weight of the boiler NOTE The KN may be installed directly on combustible flooring but never on carpeting 4 Locate the boiler in an area that will prevent water damage to adjacent construction should a leak occur or during routine maintenance 5 DO NOT place this boiler in a location that would restrict the introduction of combustion air into the unit or subject it to a negative pressure unless the combustion air is piped from the outside see the COMBUSTION AIR amp VENTILATION section 6 NEVER place this boiler in a location that would subject it to temperatures at or near freezing See the FREEZE PROTECTION SECTION on page 7 WARNING Never store combustible materials gasoline or any product containing flammable vapors or liquids in the vicinity of the boiler Failure to comply with this warning can result in an explosion or fire causing extensive property damage severe personal injury or death COMBUSTION AIR amp VENTILATION WARNING This boiler must be supplied with combustion air in accordance with Section 5 3 Air for Combustion amp Ventilation of the latest revision of the National Fuel Gas Code ANSI Z223 1 NFPA 54 and all applicable local building codes Canadian installations must comply with CSA B149 1 or 2 Installation Code for Gas Burning Appliances and Equipment or
17. 3 BLOWER FLANGE FRONT GASKET 59 1058 1 1 74 BURNER PLAQUE 45 1265 1 BURNER PLAQUE 45 1268 1 75 VIEW PORT GLASS 60 4280 1 1 76 VIEW PORT GLASS BRACKET 60 4281 1 1 77 BLOWER ASSY 58 1848 1 1 78 GAS TRAIN UPPER BRACKET 70 1332 1 GAS TRAIN UPPER BRACKET 70 1287 1 79 FLUE ADAPTER GASKET 59 2069 1 FLUE ADAPTER GASKET 01 5038 1 WIRE HARNESS ELECTRICAL KN 10 1 WIRE HARNESS DUNGS GAS VALVE 70 2024 1 1 2 WIRE HARNESS FASCO BLOWER 70 2025 1 1 3 WIRE HARNESS HONEYWELL 70 2026 1 1 4 WIRE HARNESS ON OFF SWITCH 70 2027 1 1 5 WIRE HARNESS TEKTRA TEKMAR 70 2029 1 1 6 WIRE HARNESS TRANSFORMER 70 2030 1 1 KN INSTALLATION AND OPERATION INSTRUCTIONS Page 29 HydroTherm 260 North Elm Street Westfield Mass 01085 Field Wiring the KN 6 amp KN 10 2 Screws Securing the Cover Tekmar Terminal Block lt Power Terminal Block he Cover Control Terminal Block Removable Plastic Main Circuit Board PCB Cover All field wiring on the KN 6 amp KN 10 is performed on terminal blocks located on the Main Circuit Board To access the Main Circuit Board remove the plastic front cover by removing the 2 securing screws on the left hand side and the 2 wing nuts securing the right hand side CAUTION BEFORE WIRING OR PERFORMING SERVICE WORK SHUT OFF THE GAS SUPPLY AND ALL POWER DISCONNECTS TO THE BOILER FAILURE TO FOLLOW THESE CAUTIONS COULD RESULT IN SERIOUS INJURY OR PROPERTY DAMAGE In the interest of product de
18. 42 PORT SEAL 59 1066 8 10 43 PRESSURE TEMP GAUGE 20 1020 1 1 44 LEFT SIDE UPPER JACKET PANEL 03 1605 1 LEFT SIDE UPPER JACKET PANEL 03 1701 1 45 REAR CASTING SECTION 01 1627 1 1 46 UV PIPE NIPPLE 53 1028 1 1 47 REAR EXTERNAL WIRE COVER 03 1623 1 1 48 REAR JACKET PANEL 03 1604 1 REAR JACKET PANEL 03 1688 1 49 SCANNER COOLING PUMP PROVE SW BRACKET 03 1652 1 1 50 SCANNER COOLING PUMP PROVE SWITCH 02 5208 1 1 51 IGNITION TRANSFORMER 26 3207 1 1 52 BOILER EXT NIPPLE 70 1347 1 1 FLOW SWITCH OPTIONAL 21 2101 1 1 54 REAR IGNITOR COVER ASSY 70 1336 1 1 55 VIEW PORT GLASS GASKET 59 1063 2 2 56 IGNITOR ASSY 70 1345 1 1 57 CERAMIC FIBER CHAMBER 45 1266 1 CERAMIC FIBER CHAMBER 45 1269 1 58 CERAMIC FIBER CHAMBER LOWER GASKET 59 1065 1 CERAMIC FIBER CHAMBER LOWER GASKET 59 1080 1 59 BURNER MOUNTING PLATE GASKET 59 1064 1 BURNER MOUNTING PLATE GASKET 59 1081 1 60 BURNER MOUNTING PLATE 03 1602 1 BURNER MOUNTING PLATE 03 1694 1 61 HIGH LIMIT AQUASTAT W MAN RESET 02 2802 1 1 62 BURNER GASKET 59 1060 3 BURNER GASKET 59 1082 3 63 BURNER HOLD DOWN ASSY 70 1335 1 BURNER HOLD DOWN ASSY 70 1286 1 64 BURNER SPRING 60 4292 2 2 65 BURNER SPRING RETAINER 60 4254 2 2 66 PILOT ELBOW 60 4252 1 1 67 PILOT ORIFICE NAT GAS 25 0061 1 1 68 PILOT TUBE 54 2119 1 PILOT TUBE 70 1265 69 PILOT GUIDE 60 4250 1 70 INTAKE PLENIUM 01 1630 1 INTAKE PLENIUM 01 1634 1 71 BLOWER FLANGE REAR GASKET 59 1059 1 1 72 INTAKE SPOOL ASSY 70 1337 1 1 7
19. Direct Intake Air Option General This configuration provides combustion air directly to the boiler s air intake using a dedicated pipe when using the direct vent option Combustion air can be drawn in horizontally through an outside wall or vertically through the roof see Figures 1 2 3 amp 4 It must be sized per Table 3 WARNING Each boiler must have it s own intake air system Common intake air systems are not to be used Improper installation can result in excessive levels of carbon monoxide which can cause severe personal injury or death Single wall galvanized smoke pipe single wall aluminum pipe flexible aluminum pipe PVC or CPVC pipe can be used for the intake air pipe Table 3 Intake Air Pipe Sizing Model Pipe Diameter Size in mm 600 5 127 1000 6 152 2000 9 229 All joints in metal intake air systems must be secured using corrosion resistant fasteners and sealed using a suitable Silicone caulk If PVC or CPVC is used the joints must be cleaned with a suitable solvent and connected using a solvent based PVC cement The intake air system MUST be supported by the building structure not the boiler KN INSTALLATION AND OPERATION INSTRUCTIONS Direct Intake Air Option Vertical Table 5 Horizontal Intake amp Vent System The maximum equivalent length for the vertical intake Components air pipe is 80 ft 19 7 m Each 90 mitered elbow and Company Descripti
20. ESTFIELD MA 01085 413 564 5515 FAX 413 568 9613 IN CANADA 5211 CREEKBANK RD e MISSISSAUGA ONT LAW 1R3 905 625 2991 FAX 905 625 6610 www hydrotherm com Page2 KN INSTALLATION AND OPERATION INSTRUCTIONS AVERTISSMENT Assurez vous de bien suivre les instructions donn es dans cette notice pour r duire au minimum le risque d incendie ou d explosion ou pour viter tout dommoge mat riel toute blessure ou la mort Ne pas tenter d allumer d appareil le b timent intructions du fournisseur Ne pas entreposer ni utiliser d essence ou ni d autres vapeurs ou liquides inflammables proximit de cet appareil ou de tout autre appareil QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ Ne touchez aucun interrupteur ne pas vous servir des t l phones se trouvant dans Appelez imm diatement votre fournisseur de gas depuis un voisin Suivez les Si vous ne purvez rejoindre le fournisseur appelez le service des incendies L installation et l entretien doivent tre assur s par un installateur ou un service d entretien qualifi ou par le fournisseur de gaz CONTENTS Before Your Start page 2 Ratings amp Capacities page 3 Bereit T ET page 3 Combustion Air amp Ventilation page 3 Venting Guidelines page 5 Common Vent Systems
21. IMUM 4 4 IN PER FOOT PITCH PIPE DOWN TOWARDS TERMINAL CAP 1 4 IN PER FOOT 20 mm m 20 mm m 6 FT 1 8 MINIMUM S z P 5 TO ADJACENT v om PAPE 7 5 MINIMUM MINIMUM BETWEEN TERMINALS BETWEEN TERMINALS ELBOWS OR TEES CENTER LINE CENTER LINE 1 5 FT 0 5 m MINIMUM DISTANCE FROM INTAKE TO MAXIMUM SNOW LINE Figure 2 Horizontal Air Intake and Venting for Multiple Direct Vent Systems 1001 TO 2000 29370586 10 3 1 2001 TO 4000 586 TO 1172 15 4 6 lt 4001 amp LARGER LARGER 20 6 1 5FT 1 5m MINIMUM alala COMBUSTION AIR NTAKE TERMINAL K ZIN 50cm MINIMUM aA BETWEEN TERMINALS aA man IS 1 5 FT 0 5m MINIMUM DISTANCE FROM INTAKE TO MAXIMUM SNOW LINE AAA EXHAUST TERMINAL MBH x m BANK 500 TO 1000 146 To 293 5 1 5 aar RIOM 11 KN INSTALLATION AND OPERATION INSTRUCTIONS Page 9 Figure 3 Vertical Air Intake and Venting for Direct Vent System 10FT 3 1 m MINIMUM TO WALL OR ADJOINING APPROVED SESS NORESTRICTIVE TERMINAL 1 1 4FT 1 2m 5 1 2 FT MINIMUM 1 7m MINIMUM MAXIMUM SNOW ROOF CME FLASHING HIOM 3 REV 1 CLEARANCES PER VENT MANUFACTURER S INSTRUCTIONS COMBUSTION AIR EXHAUST W ES UL CERTIFIED i 1 5m VENT SYSTEM MINIMUM Figure 4 Combination Direct Vent Systems 3 1m MINIMUM
22. ION AND OPERATION INSTRUCTIONS g Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code ANSI Z223 1 NFPA 54 When resizing any portion of the common venting system the common venting System should be resized to approach the minimum size as determined using the appropriate tables in Appendix F in the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CSA B149 Installation Codes Tout mauvais fonctionnement du syst me d vacu tion commun devrait tr corrig de fagor que l instal lation soit conforme au National Fuel Gas Code ANSI Z223 1 NFPA 54 et ou aux codes d installation CSA B149 Si la grosseur d une section du syst me d vacuation doit tr modifi e le syst me devrait tr modifi pour respecter les valeurs minimales des tableaux pertinents de l appendice F du National Fuel Gas Code ANSI Z223 1 NFPA 54 et ou des codes d installation CSA B149 GENERAL PIPING REQUIREMENTS CAUTION Improper piping of this boiler will void the manufacturer s warranty and can cause boiler failure resulting in flooding and extensive property damage NOTE Shut off valves and unions should be installed at the inlet and outlet connections of the boiler to provide for isolation of the unit should servicing be necessary Relief Valve Pipe the discharge of the pressure relief valve as shown in Figure 8 WARNING Never install any type of valve betwe
23. KN2 805 HydroTherm KN SERIES GAS BOILER INSTALLATION amp OPERATING INSTRUCTIONS e MEA 163 04 E MASS Plumbers G1 06 04 28 DESIGNED AND TESTED ACCORDING TO A S M E BOILER AND PRESSURE VESSEL CODE SECTION IV FOR A MAXIMUM ALLOWABLE WORKING PRESSURE OF 100 PSI 700 kPa WATER WARNING If the information in this manual is not followed exactly a fire or explosion may result causing property damage personal injury or loss of life Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch Do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions f you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier CAUTION Do not use automotive anti freeze in the boiler waterways If the use of antifreeze is necessary an anti freeze specifically formulated for hydronic heating systems must be used or damage to the boiler may occur voiding the warranty INSTALLER THESE INSTRUCTIONS TO BE AFFIXED ADJACENT TO THE BOILER WATER HEATER CONSUMER RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE PURPOSES HydroTherm IN UNITED STATES 260 NORTH ELM ST e W
24. RMINA S NOT REGUIRED DESIGNATION TERMINAL 15 STAGE CONTACTS STAGE 13 14 DRY PUMP CONTACTS 24 240VAC SA MAX PMP TERMINAL 16 STAGE CONTACTS STAGE LLL TERMINAL 21 s 20 22 BLOWER MODULATING SIGNAL 4 20m TERMINAL 23 24VAC STAGE ALARM OUTPUT ALARM TERMINAL 20 4 20mA OUTPUT SIGNAL NEG RC AN TERMINAL 22 4 20mA OUTPUT SIGNAL POS WG TERMINALS NOT USED BY TEKMAR 1000 Q MAX ON TERMINALS 20 22 TERMINALS 8 10 11 17 18 19 4257802 DIP SWITCH ON BACK OF CONTROL SHOULD BE SET TO 4 20mA POSITION 5 6 04
25. System Components Termination T 300314 6 Company Description Part Number Dia in Termination T 9 Flex L 5 Termination EL 5 Flex L 6 Termination EL 6 Flex L 9 Termination EL 9 Heat Fab Rain Cap 5500CI 5 Z Flex Vent Adapter 5 Heat Fab Rain Cap 5600CI 6 Vent Adapter 6 Heat Fab Rain Cap 51000CI 9 Vent Adapter 9 Pro Tech Rain Cap FSRC5 5 Termination T O2SVSTTXO5 5 Pro Tech Rain Cap FSRC6 6 Termination T 6 Pro Tech Rain Cap FSRC10 9 Termination T 9 Z Flex 5 Termination EL 5 Z Flex 6 Termination EL 6 Z Flex 9 Termination EL 9 GENERAL VENTING GUIDELINES WARNING The vent installation must be in accordance with Part 7 Venting of Equipment of the National Fuel Gas Code ANSI Z223 1 NFPA 54 latest revision or applicable provisions of the local building codes Canadian installations must comply with CSA B149 1 or 2 Installation Code Improper venting can result in excessive levels of carbon monoxide which can result in severe personal injury or death All vent systems must be fully supported by the building structure and not by the boiler Appropriate thimbles and fire stops must be used where required WARNING Each boiler must have it s own vent system Common positive pressure vent systems are not to be used Improper installation can result in excessive levels of carbon monoxide which can cause severe personal injury or death Note A single acting barometric damper must be installed in the vent connector if a vertical v
26. TO WALL OR ADJOINING BUILDING 9 APPROVED NONRESTRICTIVE MAXIMUM TERMINAL SNOW LINE ELBOW OR TEE MAXIMUM SNOW LINE 1 5 FT 0 5 m MINIMUM DISTANCE FROM INTAKE TO MAXIMUM SNOW LINE Page 10 SIDE WALL VENT POSITIVE PRESSURE CATEGORY IV In this configuration the boiler blower is used to push the flue products horizontally to the outdoors see Figure 5 Figure 5 Side Wall Venting BUILDING OVERHANG 4FT 1 2m MAX 1 5 FT 5m MINIMUM DISTANCE FROM EXHAUST TO MAXIMUM SNOW LINE VERTICAL VENT POSITIVE PRESSURE CATEGORY IV In this configuration the boiler blower is used to push the flue products vertically to the outdoors see Figure 6 The air for combustion is taken from the space in which the unit is installed The applicable instructions under the COMBUSTION AIR amp VENTILATION SECTION must be followed The vent guidelines under the VERTICAL DIRECT VENT SYSTEMS section must also be followed 11 ELLA P IZZZZZZZZZZZZZZA TIIIIMOIOOOMOLSOLSOSOSOIOMOMOMOMOMMOMOMMAMAMOMMIOMOMSOLLLL AS KN INSTALLATION AND OPERATION INSTRUCTIONS The air for combustion is taken from the space in which the unit is installed The applicable instructions under the COMBUSTION AIR 8 VENTILATION SECTION must be followed The vent guidelines under the HORIZONTAL DIRECT VENT SYSTEMS section must also be followed PITCH PIPE DOWN TOWARDS BOILER 1 4 IN PER FT 20
27. andby 1 The boiler is idle with no interlocks in the fault condition DEMAND Pre Purge 1 The blower operates at purge RPM The water flow interlock must make within 15 seconds after the demand signal is initiated 2 The Honeywell 7800 starts a 10 second purge delay once the air prove switch contacts close Pilot Run elnput 1 The blower operates at minimum input RPM 2 The ignition transformer is energized The pilot solenoid valve opens for the 10 second pilot ignition trial Main Run elnput 1 The main gas valve opens 2 The ignition transformer is de energized 3 The pilot solenoid valve closes 4 The blower stays at the minimum input RPM for 3 seconds then operates at demand input NO DEMAND Post Purge 1 The main gas valve closes 2 The blower operates at purge RPM for 10 seconds 3 The boiler is idle with no interlocks in the fault condition Page 21 Page 22 CHECKING ADJUSTMENT amp OPERATION Spark Gap The gap has to be measured and adjusted with the igniter removed from the boiler Observe the trial for ignition to confirm that the spark is strong and continuous If not check and adjust the spark gap as shown in Figure 16 Figure 16 Spark Gap 4 13 16 LL SY o o A HIOM 16 Pilot Adjsutment The pilot pressure has been factory s
28. appliances to this flue Doing so can result in excessive levels of carbon monoxide which can cause severe personal injury or death Table 7 Equivalent Breeching amp Chimney Size Negative Pressure Single Boiler Model Breech amp Flue Diameter Size in 600 8 204 1000 12 305 2000 18 457 NOTE These sizes are based on a 20 ft 6 1m chimney height Vent Connections Locate the boiler as close to the chimney system as possible Use the shortest straightest vent connector possible for the installation If horizontal runs exceed 5 ft 1 5 m they must be supported at 3 ft 0 9 m intervals with overhead hangers Use the appropriate vent connector of the same diameter as the flue collar to connect the boiler to a listed metal chimney system Follow the chimney system manufacturer s instructions for proper assembly Page 11 The vent system should be sloped up toward the chimney at a minimum rate of 1 4 in ft 2 cm m WARNING Never install a vent pipe of a diameter different than that specified in Table 7 Failure to comply with this warning can result in excessive levels of carbon monoxide which can cause severe personal injury or death Always provide a minimum clearance of 6 in 152 mm between single wall vent pipe and any combustible materials WARNING Failure to maintain minimum clearances between vent connectors and any combustible material can result in a fire causing extensive propert
29. at the gas supply piping has the capacity to meet the demand Circulator NOTE Not all system valves may be shown Consult local codes for additional system components which may be necessary 9 0 Vacuum Relief Thermometer Expansion Aquastat Relief Valve Valve Tank HIOM 13 REV 1 Figure 14 depicts the proper way to connect the boiler to the gas supply piping The manual shut off valve MUST be installed in the supply piping It should be installed 5 feet above the floor where required by local codes Provide a sediment trap at the bottom of the vertical section of the gas supply pipe upstream of the gas controls A ground joint union should be installed between the boiler gas controls and the supply piping Each of these items are needed to ensure long life and ease of servicing Always use a pipe sealant that is suitable for use with LP gas Table 9 Gas Pipe Capacity Maximum pipe capacity in ft hr based on 0 60 specific gravity gas ata pressure of 0 5 psig or less and a 0 3 WC pressure drop Nominal Pipe length in feet Iron Pipe 10 20 30 40 50 60 80 100 150 Size in Maximum gas volume of pipe ft hr 1 520 350 285 245 215 195 170 150 120 114 1050 730 590 500 440 400 350 305 250 11 2 1600 1100 890 760 670 610 530 460 380 2 3050 2100 1650 1450 1270 1150 990 870 710 Note Multiply the gas volume by 0 62 for propane flow capacity in ft hr M
30. ates that the UV scanner air pump proving switch is open with the boiler running STANDBY TEKTRA ALARM Indicates a problem with the Tekmar operating control without a call for heat LOCKOUT TEKTRA ALARM Indicates a problem with the Tekmar operating control with a call for heat LWCO LOCKOUT Indicates low or no water in the boiler Page 23 Page 24 MAINTENANCE WARNING Disconnect electrical power and close the manual gas shut off valve before performing maintenance or severe personal injury may result CAUTION Servicing inspection and adjustment must be done by a trained technician in accordance with all applicable local and national codes Improper servicing or adjustment can damage the boiler The boiler must be cleaned and inspected at least once a year and before each heating season Make sure that the burner and ignition components are free from dust soot dirt corrosion or other deposits that would impair the boiler s performance Refer to page 26 for component identification CAUTION Improper burner servicing can result in premature burner failure voiding the warranty Burner Removal amp Inspection WARNING The ceramic combustion chamber in the burner box and its gasket contain crystalline silica Wear a tightly fitted dust mask when servicing the burner and gently handle the burner and its gasket to prevent inhalation of airborne fibers Crystalline silica fibers have been identified as carcino
31. ccur do not operate the boiler until the problem is solved or severe personal injury or death may occur Page 25 Figure 18 Main Burner Flame TIGHT BLUE FLAME HIOM 18 DX UNI ao YELLOW FLOATING FLAME TROUBLESHOOTING OPERATIONAL PROBLEM CORRECTIVE ACTION The Power On light doesn t illuminate Ensure that proper voltage is being supplied to the unit Inspect the circuit breaker for the boiler circuit Check the light Ensure that the power switch operates properly and is wired correctly Lockout water limit is displayed with a call for heat Check both the high limit and low water cut off Ensure that the boiler has been completely purged of air Ensure that all system valves are in the correct position Lockout gas pressure is displayed with a call for heat Ensure that the manual main gas valve is open Ensure that there is sufficient gas pressure supplying the boiler Check pressure setting on the low gas pressure switch Lockout flow switch is displayed with a call for heat Ensure that there is sufficient water flow through the boiler UV scanner switch is displayed flashing along with the normal running display Ensure the scanner cooling pump is operating Make sure there are no obstructions in the tubing supplying the air to the scanner Lockout Tektra alarm is displayed with a call for heat There is a problem with the
32. d States ULS636 for installations in Canada The vent terminals listed in Table 4 must also be used Below is a list of some of the manufactures that have systems that meet these requirements Others manu facturers that have UL certified systems may be used Heat Fab Inc 38 Hayward Street Greenfield MA 01301 800 772 0739 Z Flex U S Inc 20 Commerce Park North Bedford NH 03110 6911 800 654 5600 Protech Systems Inc 26 Gansevoort Street Albany NY 12202 518 463 7284 Flex L International Inc 6385 Kennedy Road Missis sauga ON Canada L5T 2W4 800 561 1980 The maximum equivalent length for the vertical vent pipe is 80 ft 19 7 m Each 90 elbow and the intake air cap are equal to 10 ft 3 3 m of straight pipe If any part of a single wall metal vent system passes through an unheated space it must be insulated with insulation rated for 400 F 204 C Structural penetrations must be made using approved fire stops The top of a vertical vent system must extend at least 51 2 ft 1 8 m above the roof surface that it passes through 4 ft 1 3 m above the intake air cap see Figure 3 In addition the vent system must conform to the dimensions shown in Figure 3 The penetration point in the roof must be properly flashed and sealed The vent system must be gas tight All seams and joints in metal pipes must be joined and sealed in accordance with the vent system manufacturer s instructions Combination Direct Vent Sys
33. eat The boiler will start to go through it start up sequence During the ignition pilot sequence observe the lights on the Honeywell 7895C The pilot light should come on but not the flame light If the flame light comes on along with the pilot light interrupt the call for heat and turn off the main power Reverse the 120v supply leads to the Honeywell 652B ignition transformer and run this test again With this done the flame signal should be between 3vdc and 5vdc Check the voltage on the test connections of the Honeywell 7895C s amplifier with a dc voltmeter Main Burner Combustion The fuel mixture on full fire is not adjustable The CO was checked at the factory and should be approximately 8 5 to 8 8 However if the CO is well out of this range something is wrong Check if the end of the gas pipe is centered in the 2 x 5 air orifice in the filter box The end of the pipe should be centered in and square to the opening and it should be inserted by approximately 3 8 Also make sure the entire gas train is secured tightly to its support arms The fuel air mixture on min or low fire is adjustable This mixture was set at the factory to match that of the full fire Therefore the CO should be approximately the same over the entire firing range KN INSTALLATION AND OPERATION INSTRUCTIONS To confirm the input of the unit follow the instructions in the INPUT RATE section below 1 A flue gas sample must be taken at the flue outle
34. ed Failure to comply with this warning can result in excessive levels of carbon monoxide causing severe personal injury or death All Air From Inside The Building If the boiler is to be located in a confined space the minimum clearances listed in Table 1 must be maintained between it and any combustible construction When installed in a confined space without the intake air option two permanent openings communicating with an additional room s are required The combined volume of these spaces must have sufficient volume to meet the criteria for an unconfined space The total air requirements of all gas utilization equipment fireplaces wood stoves or any type of exhaust fan must be considered when making this determination Each opening must have a minimum free area of 1 in 1000 Btu hr 2200 mm kW based on the total input rating of ALL gas utilization equipment in the confined area Each opening must be no less than 100 in 64 516 mm in size The upper opening must be within 12 in 300 mm of but not less than 3 in 80 mm from the top of the enclosure The bottom opening must be within 12 in 300 mm of but not less than 3 in 80 mm from the bottom of the enclosure All Air From Outside The Building When installed in a confined space without the intake air option two permanent openings communicating directly with or by ducts to the outdoors or spaces that freely communicate with the outdoors must be present The upper opening mu
35. en the boiler and the relief valve or an explosion causing extensive property damage severe personal injury or death may occur Flow Switch The flow switch supplied with the boiler is wired to prevent the boiler from firing unless there s adequate water flow through the unit NOTE Failure to maintain a minimum flow rate of 30 gpm 7 9 L s at the boiler outlet will prevent the flow switch from closing If a minimum flow rate of 30 gpm 1 9 L s cannot be maintained at the boiler outlet the flow switch will have to be relocated in the system Figure 8 Relief Valve Piping DISCHARGE PIPE SIZE TO EQUAL VALVE OUTLET DO NOT RESTRICT FLOW HIOM 8 REV 1 DISCHARGE SO AS TO AVOID EXPOSURE OF PERSONS TO HOT LIQUID OR VAPOR AND ALLOW COMPLETE DRAINAGE OF RELIEF VALVE AND PIPING HEATING SYSTEM PIPING General Piping Requirements All heating system piping must be installed by a qualified technician in accordance with the latest revision of the ANSI ASME Boiler and Pressure Vessel Code Section IV Where required the piping must comply with ANSI ASME CSD 1 Standard for Controls and Safety Devices for Automatically Fired Boilers All applicable local codes and ordinances must also be followed A minimum clearance of 1in 25 mm must be maintained between heating system pipes and all combustible construction All heating system piping must be supported by suitable hangers not the boiler The thermal expansion of the sys
36. ent system produces a draft in excess of 0 08 in 2 03 mm W C at the flue outlet Note One of the vent system adapters listed in Table 5 must be attached to the flue outlet of the boiler before the vent system is connected Page 5 Page 6 VENT SYSTEM OPTIONS The KN may be vented the following ways 1 Direct Vent Positive Pressure Category IV uses a vent system certified to UL 1738 for installations in the United States ULS636 for installations in Canada Combustion air is piped from the outdoors to the blower inlet 2 Side Wall Vent Positive Pressure Category IV uses a stainless steel vent system certified to UL 1738 for installations in the United States ULS636 for installations in Canada Combustion air is obtained from the space in which the unit is installed 3 Vertical Vent Positive Pressure Category IV uses a stainless steel vent system certified to UL 1738 for installations in the United States ULS636 for installations in Canada Combustion air is obtained from the space in which the unit is installed 4 Vertical Vent Negative Pressure Category Il uses an approved metal chimney system Combustion air is obtained from the space in which the unit is installed DIRECT VENT POSITIVE PRESSURE CATEGORY IV In this configuration the boiler blower is used to push the flue products to the outdoors while drawing combustion air from the outdoors The INTAKE AIR OPTION instructions under the COMBUSTION AIR
37. ere met with the gas manifold and control assembly provided on the boiler All gas connections MUST be leak tested before putting the boiler into operation WARNING Never use an open flame to test for gas leaks Always use an approved leak detection method Failure to comply with this warning can cause extensive property damage severe personal injury or death Whenever the gas supply piping is pressure tested the boiler gas controls must be protected If the test pressure is equal to or less than 1 2 psig 3 5 kPa isolate the boiler by closing its manual shut off valve see Figure 14 If the test pressure is greater than or equal to 1 2 psig 3 5 kPa disconnect the boiler and its individual shut off valve KN INSTALLATION AND OPERATION INSTRUCTIONS ELECTRICAL WIRING Electrical Power Connections CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing ATTENTION Au moment de l entretien des com mandes tiquetez tous les fils avant de les d brancher Des erreurs de c blage peuvent entrainer un fonctionnement inad quat et dangereux S assurer que l appareil fonctionne ad quatement une fois l entretirn termin The electrical connections to this boiler must be made in accordance with all applicable local codes and the latest revision of the National Electrical Code ANSI NFPA 70 Installation should
38. ers used for typical field connections Table 2 lists terminals not typically used These are identified for the purposes of troubleshooting or for special applicactions For further details consult the Tekmar manual NOTE All field wiring and components are supplied by the customer or installer All field wires shall be a minimum of 18AWG wire type shall be MTW 600V stranded with insulation rated for 105 C or equivalent 42 5780 1 5 6 04 KN INSTALLATION AND OPERATION INSTRUCTIONS OPERATOR MAIN PCB TOP VIEW TERMINAL 7 POWER TERMINAL BLOCK POWER SERVICE 120V 60 HZ 1 PH FLA 8 0 MAIN CIRCUIT BOARD PCB NOTE TERMINAL BLOCKS UNPLUG FOR EASY WIRING LIFT CAP TO ACCESS SCREWS Andino G3HOLIMS JVA 021 S Z c E4 5 HOIH LEGEND FIELD WIRING FACTORY WIRING NOTE FOR COMPLETE WIRING DETAILS SEE DRAWINGS 42 5777 1 B 42 5777 2 B FIGURE 1 FIGURE 2 MODULATING USING HI FIRE STAGING USING 4 20mA SIGNAL TERMINALS T T MODULATION RATE X Page 31 HydroTherm KN 6 amp KN 10 FIELD WIRING DIAGRAM Units With Remote Panel Control INTERLOCK TERMINAL BLOCK 14AWG WIRE MAX CONTROL TERMINAL BLOCK TRANSMITTER WITH INTERNAL POWER SUPPLY TYPE 4 SEE FIGURE 3 FOR OTHER TRANSMITTER TYPES ALARM INDICATORS L _ 5AMP_MAX TO SUITABLE ALARM POWER SOURCE FIGURE 3 Type 2 Use contacts to shut boiler off if minimum signal strength never drops
39. et at 1 5 and shouldn t need adjustment To check the pilot pressure close the manual main shut off valve 2 and the pilot gas shut off valve Figure 14 Remove the 1 8 pipe plug from the pilot tee and connect a manometer having a minimum range of 6 in 154 mm WC to it the Open the pilot gas shut off valve With the unit powered generate a call for heat When the prepurge is complete the ignition pilot trial will begin At this point put the Honeywell 7895C test switch in the test position The control will hold in the ignition pilot sequence allowing you to check the pressure To adjust the pilot the following steps must be taken 1 Remove the pilot gas pressure regulator cap 2 Turn the pressure regulator adjustment screw clock wise to increase the pressure and counterclockwise to decrease it 3 Replace the pressure regulator adjustment screw cap CAUTION Never force the regulator adjustment screw beyond the stop limits or damage to the regulator will occur KN INSTALLATION AND OPERATION INSTRUCTIONS Figure 17 Pilot Flame 1 1 2 TO 2 LONG 1 TO 1 1 2 DIA BLUE FLAME PILOT TUBE BURNER PLAQUE PILOT FLAME HIOM 17 Pilot flame UV signal Before you check the pilot signal you need to make sure the polarity of the 120v supply to the ignition transformer is correct To do this close the manual main shut off valve 2 Figure 14 and the manual pilot shut off valve With the unit powered generate a call for h
40. genic or possibly carcinogenic when inhaled NOTE Do not attempt to remove the burner without having a burner gasket kit on hand 1 Close the manual shutoff valves in the gas supply line and turn off electrical power to the boiler 2 Disconnect the pilot line Disconnect the blower filter box assembly from the blower adapter 3 Loosen the two screws on the filter box support bracket below the filter box 4 Remove the top casting 5 Remove the burner retaining nuts and springs 6 Remove the flow director 7 Carefully lift the burner out of the unit 8 Inspect the burner for damage or dirt buildup KN INSTALLATION AND OPERATION INSTRUCTIONS 9 If the burner is dirty use a vacuum to clean it If the burner has become extremely dirty it may need to be replaced 10 DO NOT reinstall a damaged burner Replace it 11 Replace all old gaskets with new ones from the burner gasket kit 12 Reassemble the unit following the removal steps in reverse order Heat Exchanger Cleaning In the unlikely event that the heat exchanger becomes blocked consult the factory for the proper cleaning procedure Air Intake amp Vent System Thoroughly inspect the air intake and vent systems for any signs of blockage corrosion or leakage Immediately replace any unsound vent system piping Inspect the air filter and wash with warm water and soap if dirty Controls Use the BOILER OPERATION and CHECKING AND ADJUSTMENT sections
41. k the rating plate to ensure that the unit has been sized properly for the job Also ensure that the unit has been set up for the type of gas available at the installation site Other important considerations are the availability of an adequate electrical supply fresh air for combustion and a suitable chimney or vent system BOILER LOCATION 1 This boiler is suitable for indoor installations only Locate the boiler in an area that provides good access to the unit Servicing may require the removal of jacket panels Allow the minimum clearances between adjacent construction and the boiler as listed in Table 1 NOTE Service clearances are not mandatory but are recommended to ensure ease of service should it be required Table 1 Clearances Clearance to Service Combustibles Clearance in mm in mm Top 6 153 24 610 Back 6 153 24 610 Left Side 6 153 24 610 Right Side 6 153 24 610 Front 6 153 36 914 Flue 6 153 2 An optimum site will be level central to the piping System close to a chimney or outside wall and have adequate fresh air for combustion Ensure that the unit is level from front to back and from side to side Use metal shims if leveling is required Electrical and electronic components must be protected from exposure to water during operation and maintenance DO NOT install this boiler in a location that would subject any of the gas ignition and other electronic components to direct contact with
42. light up when the power is on If all interlocks are properly closed the display will say Standby KN 10 Figure 15 Move the slide switch below the display to Min hold Figure 15 Create a full input demand be jumping the AA terminals or applying 20 ma to the current input terminals Figure 15 The boiler will begin the start sequence Figure 15 Control Panel CUSTOMER ON OFF TEKMAR MAIN CONNECTIONS SWITCH DISPLAY DISPLAY o k tektra BTCMPA Honeywell CALIBRATE HONEYWELL SWITCH VARIABLE DISPLAY FREQUENCY HONEYWELL B T U DRIVE RESET BUTTON ADJUSTMENT HIOM 15 KN INSTALLATION AND OPERATION INSTRUCTIONS 15 When the main display reads PIOLT RUNNING and the flame current is 5VDC switch the Honey well 7800 to the test position Figure 15 This will hold the Honeywell 7800 in its ignition state 16 Adjust the pilot pressure per the CHECKING ADJUSTMENT amp OPERATION section below 17 Remove the demand from the 7800 control allowing the boiler to stop 18 Remove the manometer fitting from the pilot tee and replace the plug Close manual main shut off valve 2 and the pilot gas shut off valve Figure 14 19 Switch the Honeywell 7800 back to run 20 Create a full input demand as before The boiler will begin the start sequence 21 Monitor the flame current on the 7800 No flame current should be detected and the 7800 should lock out If flame current is
43. low through the boiler Systems using multiple boilers can be installed using a primary secondary manifold system Figure 10 Reverse Return Piping Systems using multiple boilers can also be installed using a reverse return system Figure 11 Piping For Use With Cooling Units The boiler when used in connection with a refrigeration System must be installed so the chilled medium is piped in parallel with the boiler Appropriate valves must be used to prevent the chilled water from entering the boiler When a boiler is connected to a heating coil that may be exposed to refrigerated air from an air handling device the piping system must be equipped with flow control valves or some other automatic means of preventing gravity circulation of the boiler water during the cooling cycle NOTE Minimum boiler flow rate is 15 gpm Maximum boiler flow rate is 150 gpm Figure 9 Typical Single Boiler Primary Secondary Piping SYSTEM 12 IN 305 mm MAX SYSTEM seat NOTE Not all system valves may be shown Consult local codes for additional system components which may be necessary COLD WATER MAKE UP NIN Backflow Prevention Pressure Relief Valve Pump Gate Valve I Device MERCY RETURN 9 9 Pressure FAURE Reducing Valve Thermometer Expansion Tank HIOM 9 REV 2 KN INSTALLATION AND OPERATION INSTRUCTIONS Page 15 Figure 10 Typical Multiple Boiler Primary
44. ly tested for a maximum working pressure of 100 psi 700 kPa in accordance with Section IV of the A S M E Boiler and Pressure Vessel Code All aspects of the boiler installation must conform to the requirements of the authority having jurisdiction or in the absence of such requirements to the National Fuel Gas Code ANSI Z223 1 NFPA 54 latest revision Where required by the authority having jurisdiction the installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME CSD 1 If installed in the Commonwealth of Massachusetts you MUST FOLLOW the additional instructions contained in HydroTherm s instruction sheet MACODE 1 If you don t have a copy call your HydroTherm distributor or HydroTherm In Canada the installation must be in accordance with the requirements of CSA B149 1 or 2 Installation Code for Gas Burning Appliances and Equipment The owner should maintain a record of all service work performed with the date and a description of the work done Include the name of the service organization for future reference Direct all questions to your HydroTherm distributor or contact the HydroTherm Customer Service Department at 260 North Elm Street Westfield MA 01085 Always include the model and serial numbers from the rating plate of the boiler in question KN INSTALLATION AND OPERATION INSTRUCTIONS RATINGS amp CAPACITIES Before installing the KN boiler chec
45. nction properly Test in accordance with the manufacturer s instructions included with the device s DIAGNOSTICS The KN has a display that indicates the sequence of operation Figure 15 The display will also list faults should the unit fail to operate An explanation of each fault is listed below STANDBY KN 10 Indicates that power is being supplied to the unit and there is no call for heat STANDBY OPERATING LIMIT Indicates that the operating limit if used is open HONEYWELL ALARM flashing Indicates that there is a call for heat and the Honeywell 7895C is locked out STANDBY START DEMAND Indicates that there is a call for heat and the Honeywell 7895C is not functioning or is locked out STANDBY WATER LIMIT Indicates that either the high limit low water cut off or both are open without a call for heat LOCKOUT WATER LIMIT Indicates that either the high limit low water cut off or both are open with a call for heat STANDBY GAS PRESSURE Indicates that the low gas pressure switch or the high gas pressure switch if used is open without a call for heat LOCKOUT GAS PRESSURE Indicates that the low gas pressure switch or the high gas pressure switch if used is open with a call for heat STANDBY FLOW SWITCH Indicates that the water flow switch is open without a call for heat OPTIONAL LOCKOUT FLOW SWITCH Indicates that the water flow switch is open with a call for heat UV SCANNER SWITCH flashing Indic
46. nition device which automatically lights the pilot Do not try to light the pilot by hand Cet appareil est muni d un dispositif d allumage qui allume automatiquement la veilleuse Ne tentez pas d allumer la veilleuse manuellement Page 19 B BEFORE OPERATING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not tough any electric switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas suppliers instructions If you cannot reach your gas supplier call the fire department AVANT DE FAIRE FONCTIONNER reniflez tout autour de l appareil pour d celer une odeur de gaz Reniflez pr s du plancher car certains gaz sont plus lourds que l air et peuvent s accumuler au niveau du sol QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ Ne pas tenter d allumer d appareil Ne touchez aucun interrupteur ne pas vous servir des t l phones se trouvant dans le b timent Appelez imm diatement votre fournisseur de gaz depuis un voisin Suives les instructions du fournisseur Si vous ne pouvez rejoindre le fournisseur appelez le service de incendies C Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any par
47. on Part Number Dia in the intake air cap are equal to 10 ft 3 3 m of straight Flex L Vent Adapter 5 pipe If 90 long sweep elbows are installed use the Flex L Vent Adapter 6 manufacturers recommended equivalent length Flex L Vent Adapter 9 Termination T A listed nonrestrictive intake air cap must be used The Termination T intake air cap must terminate as shown in Figure 3 The Termination T penetration point in the roof must be properly flashed Termination EL and sealed Approved caps are listed in Table 4 Termination EL Termination EL Direct Intake Air Option Horizontal Heat Fab Vent Adapter 9501KN10 5 The maximum equivalent length for the horizontal intake Heat Fab Vent Adapter 9601KN10 6 air pipe is 80 ft 19 7 m Each 90 mitered elbow and Heat Fab Vent Adapter 91001KN10 9 the intake air terminal are equal to 10 ft 3 3 m of Termination T 9590TEE 5 straight pipe If 90 long sweep elbows are installed use Termination T 9690TEE 6 the manufacturers recommended equivalent length Termination T 90990TEE 9 Termination EL 7514TERM 5 Horizontal runs that exceed 5 ft 7 5 m must be Termination EL 9614TERM 6 supported at 3 ft 0 98 m intervals with overhead Termination EL 90914TERM 9 hangers The intake air terminal must terminate as Pro Tech Vent Adapter 5 shown in Figures 1 2 or 4 Approved terminals are listed ProTech Vent Adapter FSA HFAG 6 in Table 5 ProTech _ Vent Adapter 9 Termination T 300313 5 Table 4 Vertical Intake amp Vent
48. ower will start to run at 4mA and will reach maximum air flow at 20mA To turn the blower off open the contact across these terminals or assure the signal drops below 3 8mA See Figures 2 amp 3 24 VDC POWER SUPPLY Pg 4 The KN 6 amp KN 10 has a built in power supply for 4 20mA transmitters that do not have an internal power supply The power supply is suitable for Tansmitter Type 2 or Transmitter Type 3 This power supply is accessed on the terminal labeled 24VDC Actual voltage output may reach 32 VDC Terminal 8 is a shared common terminal for the 4 20mA signal and the 24 VDC power supply The KN 6 amp KN 10 power supply must only be used for powering a transmitter loop for the 4 20mA signal DO NOT use this power supply for any other application or for any boiler controls requiring 24 VAC power ALARM CONTACTS The Alarm terminals are connected to dry contacts Rated for 5 Amps 115 VAC maximum resistive loads Installer must connect terminals to a power supply suitable for the alarm devices used POWER Use the Power Terminal Block J1 to connect 120 VAC 1 phase 60 cycle power to the boiler This Terminal Block is removable to aid in wiring Lift up cap to access terminal screws Do not exceed 12AWG wire TEKMAR TERMINAL BLOCK Use the Tekmar terminal block J10 when making connections for units equipped with the optional Tekmar control See following pages for the wiring diagram for these units Table 1 lists the terminal numb
49. re that all bleed and drain valves are closed Adjust the make up water pressure regulator so a minimum 12 psig 84 kPa system pressure is maintained at the highest point in the system piping If a make up water pump is used adjust it as stated above Open the system bleed and drain valves one at a time to purge the air trapped in the heating system piping With the boiler off run the system pump for at least 30 minutes and bleed the system piping using the bleed valves If strainers are used in the system piping the make up water valve should be closed and the strainers checked and cleaned The system expansion tank should be checked to ensure that tank air pressure equals cold static fill pressure Start the boiler as described in the OPERATING INSTRUCTIONS below Run the boiler for at least an hour The system pump s and all radiation units must be operated during this time Ensure that the make up water valve is open Shut the boiler off and open the bleed valves to purge the air trapped in the heating system piping Close the make up water valve and check and clean the strainers and make up water pressure reducing valve Open the make up water valve and adjust the system pressure if necessary The system should be checked and bled after three days of operation OPERATING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE OPERATING POUR VOTRE S CURIT LISEZ AVANT DE METTRE EN MARCHE A This appliance is equipped with an ig
50. ssurer que ces ventilateurs fonctionnent la vitesse maximale Ne pas faire fonctionner les ventilateurs d t Fermer les registres des chemin es Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously Mettre l appareil inspect en marche Suivre les instructions d allumage R gler le thermostat de facon que l appareil fonctionne de fa on continue Test for spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle or smoke from a cigarette cigar or pipe Faire fonctionner le br leur principal pendant 5 min ensuite d terminer si le coupe tirage d borde l ouverture de d charge Utiliser la flamme d une allunette ou d une chandelle ou la fum e d une cigarette d un cigare ou d une pipe After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous condition of use Une fois qu il a t d termin selon la m tode indiqu e ci dessus que chaque appareil raccord au syst me d vacuation est mis l air libre de fa or ad quate Remettre les portes et les fen tres les ventilateurs les registres de chemin es et les appareils au gaz leur position originale KN INSTALLAT
51. st be within 12 in 300 mm of but not less than 3 in 80 mm from the top of the enclosure The bottom opening must be within 12 in 300 mm of but not less than 3 in 80 mm from the bottom of the enclosure Where directly communicating with the outdoors or communicating with the outdoors through vertical ducts each opening shall have a minimum free area of 1 in 4000 Btu hr 550 mm kW of the total input rating of all of the equipment in the enclosure Where communicating with the outdoors through hori zontal ducts each opening shall have a minimum free area of 1 in 2000 Btu hr 1100 mm kW of the total input rating of all of the equipment in the enclosure KN INSTALLATION AND OPERATION INSTRUCTIONS When ducts are used they must have the same cross sectional area as the free area of the opening to which they connect Table 2 Make up Air Duct Sizing Required Cross Sectional Duct Area Input 1 4 in 6 4 mm Metal Wooden MBH Wire Screen Louvers Louvers in cm in cm in cm 600 150 967 200 1292 600 3869 1000 250 7672 334 2154 1000 6448 2000 500 3224 668 4308 2000 12 896 When calculating the free area necessary to meet the make up air requirements of the enclosure consideration must be given to the blockage effects of louvers grills and screens Screens must have a minimum mesh size of 1 4 in 6 4 mm f the free area through a louver or grill is not known ducts should be sized per Table 2 above
52. t using a calibrated flue gas analyzer Allow the unit to run for 15 minutes before taking the sample For a natural gas unit the CO reading should be 8 5 8 8 An LP unit will have CO readings proportionally higher 2 To test the ignition safety shutoff device close the manual shutoff valve 1 Figure 14 in the gas supply line Within 5 seconds of main burner flame extinction the main gas valve solenoid should close The control board will lockout and display LOW GAS PRESSURE Open the manual shutoff valve in the gas supply line and reset the control board by toggling the power switch Input Rate Natural Gas 1 Turn off all other gas appliances that use the same gas meter as the boiler 2 Call your gas supplier and ask for the heating value of the gas Btu per cu ft 3 Start the boiler and let it run for 15 minutes 4 With the boiler operation clock the time that it takes to burn 10 cu ft of gas at full fire 5 Insert the heating value and the time in seconds into the formula below 6 Input 10 seconds Btu per cu ft 3600 7 If the computed rate exceeds the desired input rate or 1 000 000 Btu hr reduce the input To do this use the maximum Btu adjustment pot located on the face of the display Figure 15 CAUTION Never increase the input to the boiler above that for which it is rated Doing so can cause premature failure of the boiler Low Water Cutoff Ensure that the low water cutoff device s fu
53. t of the control system and any gas control that has been under water N utilisez pas cet appareil s il a t plong dans l eau m me partiellement Faites inspecter l appareil par un tecnicien qualifi et remplacez toute partie du syst me de contr le et toute commande qui ont t plong s dans l eau Operating Instructions 1 STOP Read the safety information above If at any time the appliance will not operate properly follow the instructions TO TURN OFF GAS TO APPLIANCE and call your service technician or gas supplier 2 Set the operating control to off or its lowest setting 3 Turn off all electric power to the appliance 4 Remove the front plastic cover 5 Close manual main shut off valves 1 and 2 and the pilot gas shut off valve Figure 14 Page 20 6 10 11 12 13 14 Purge the gas piping up to the manual valve ahead of the main gas control of air When the bleeding is complete check all gas joints up to the gas valve for leaks Install a fitting at the bleed point and connect a manometer having a minimum range of 20 in 508 mm WC to it Figure 14 Remove the 1 8 pipe plug from the pilot tee and connect a manometer having a minimum range of in 154 mm WC to it Wait five 5 minutes to clear out any gas Open the manual main shut off valves 1 and 2 and the pilot gas shut off valve Figure 14 Turn the power switch on the front of the boiler to on It will
54. tem must be considered when supporting the system A minimum system pressure of 12 psig 84 kPa must be maintained at the highest point in the system piping Page 13 Page 14 Boiler Piping Connections The supply and return connections should be sized to suit the system see Table 8 Table 8 Supply amp Return Pipe Sizing Model Supply Return Size Size Size 600 2 NPT 2 NPT 1000 3 NPT 3 NPT 2000 3 NPT 3 NPT Pump Requirements This boiler requires a continuous minimum water flow for proper operation The system pump must be sized to overcome the head loss of the boiler and the heating System in order to achieve the required temperature rise If the system contains hydronic antifreeze this must be considered when sizing the pump The temperature rise across the boiler must never exceed 100 F 55 6 C Low Water Cutoff Each KN boiler comes equipped with a factory installed low water cutoff Expansion Tank amp Air Separator An expansion tank or other means to control thermal expansion must be installed in the heating system An expansion tank must be installed close to the boiler on the suction side of the pump An air scoop and automatic air vent must also be installed to eliminate air trapped in the system KN INSTALLATION AND OPERATION INSTRUCTIONS Primary Secondary Piping Figure 9 shows a typical primary secondary piping system A dedicated pump is used to maintain a constant water f
55. tems see Figure 4 The boiler can be vented vertically with the intake air piped horizontally through an outside wall Follow the instructions in the INTAKE AIR OPTION HORIZONTAL GUIDELINES on page 4 Also follow the general instructions in the COMBUSTION AIR amp VENTILATION and GENERAL VENTING GUIDELINES sections KN 10 Multiple Boiler Venting Category II Venting Negative DOUBLE ACTING BARAMETRIC DAMPER ALL CONNECTIONS Je TO BE T WYE m a D 6 FLUE OUTLET Table 1 Common Vent Sizes COMMON VENT SIZE IN A COMMON AIR NUMBER OF MR INLET IN D MAX 80 12 14 16 18 afa jajn N Table 2 Vent Lengths HORIZONTAL MINIMUM LENGTH ft VERTICAL B LENGTH ft BOILER 5 BOILER 4 BOILER 3 IF REQUIRED IF REQUIRED IF REQUIRED HIOM 21 BOILER 1 BOILER 2 ALWAYS LEAD Page 7 NOTE A NEGATIVE PRESSURE OF 02 TO 08 MUST BE PROVIDED FOR ALL BOILERS CONNECTED TO THE BREECHING WHEN ALL BOILERS ARE IN OPERATION AT FULL INPUT Page 8 KN INSTALLATION AND OPERATION INSTRUCTIONS Figure 1 Horizontal Air Intake and Venting for a Single Direct Vent System BUILDING OVERHANG 4FT PITCH PIPE DOWN 1 2m TOWARDS BOILER MAX
56. ts must be suitable for use with potable water The indirect storage tank must be equipped with a temperature and pressure relief valve that complies with ANSI Z21 22 or CAN 4 4 and CAN 4 6 KN INSTALLATION AND OPERATION INSTRUCTIONS NOTE The storage tank must be located as close to the boiler as possible to prevent excessive head loss which will reduce flow Expansion Tank An expansion tank or other means to control thermal expansion must be installed in the water heating system if back flow prevention devices are installed Two typical water heating systems are shown in Figures 12 amp 13 Thermostatic Mixing Valve Water Above 140 F 60 C Water can be stored a temperatures above 140 F 60 C provided that a thermostatically controlled mixing valve is used to temper the hot water to an acceptable temperature before it s supplied for domestic use The mixing valve MUST be set to prevent a scald injury from occurring see the caution against scalding above Storage of water for domestic use above 140 F 60 C will provide an increased quantity of tempered water and help prevent the growth of water born bacteria Figure 12 Typical Single Boiler with Indirect Storage Tank Piping SUPPLY COLD WATER MAKE UP Bronze Pump FLOW Circulator Return Oot N NIN COLD WATER MAKE UP FLOW NOTE Not all system valves may be shown Consult local codes for additional system components which may be necessary Y
57. ultiply the propane flow capacity by 2500 Btu ft3 to determine the propane Btu hr capacity for a given pipe size and length Page 17 Page 18 Table 10 Equivalent Pipe Length Chart Type of pipe fitting Nominal Iron Pipe 90 Elbow Tee Gas Valve Gas Cock Size in Equivalent pipe length ft 1 2 6 5 2 0 6 1 5 11 4 3 5 6 9 0 8 1 9 112 4 0 8 0 0 9 2 3 2 5 2 10 3 1 2 3 0 Notes 1 For flow through branch 2 For flow at full open Figure 14 Gas Supply Piping GROUND JOINT UNIONS PILOT SHUTOFF VALVE PILOT VALVE SOLENOID FROM GAS SUPPLY TEST PORT Bis PILOT REGULATOR PRESSURE ADJUSTMENT CIS Br HIOM 14 LN L MODULATING GAS VALVE MANUAL SHUTOFF VALVE 1 ON su TRAP amp DRIP LEG MANUAL SHUTOFF VALVE 2 NOTE An inline gas regulator must be installed up stream of the gas train and set to the lowest expected service pressure Choose a regulator that has no more than 1 pressure drop CAUTION Always use a wrench on the gas valve body when making gas connections to it Never over tighten the piping entering the gas valve body or gas valve failure may result Safe lighting and other performance criteria w
58. velopement this wiring guide is subject to change without notice 42 5780 1 5 6 04 Page 30 KN INSTALLATION AND OPERATION INSTRUCTIONS BALLOON CALLOUT NUMBER See Diagrams on following pages STAGE FIRING The KN 6 amp KN 10 can be stage fired by controlling dry contact closure across the T1 or T2 terminals Either pair of terminals will fire the boiler at half the rated input when the dry contacts close To achieve maximum efficiency when staging multiple boilers fire all the boilers on Lo Fire first Use contact closure on the T1 terminals for each boiler After all the boilers are firing on LO Fire begin staging individual boilers to Hi Fire with contact closure on T2 The boiler can be fired directly to Hi Fire in three ways Simultaneous contact closure on T1 and T2 jumping terminals 1 to 3 and staging with a dry contact across terminals 1 and 2 See figure 1 or using the AA terminals PRIORITY ZONE The A A terminals can be used for Priority Zone Hi Fire staging Contact closure across the A A terminals will override the 4 20mA input signal and will take priority MODULATING Pg 4 The 4 20mA terminals are used for linear modulation control of the blower motor Due to the Air Fuel Coupling the gas valve automatically adjust gas flow to match the air flow generated by the blower These terminals are used with Transmitter Type 4 controls that have an internal power supply Example The Tekmar BTC MPA supplied as an option The bl
59. y damage severe personal injury or death Figure 7 Vertical Venting with a Metal Chimney System i 2FT 6m ABOVE THE HIGHEST POINT WITHIN 10FT 3 1m STORM COLLAR ROOF FLASHING CLEARANCES PER VENT MANUFACTURER S INSTRUCTIONS OFFSET ONLY IF NECESSARY FIRESTOP FRAMING MEMBERS JOIST BETWEEN JOISTS s CLEARANCES PER VENT MANUFACTURER S INSTRUCTIONS lll BOILER HIOM 7 Page 12 COMMON VENT SYSTEMS If an existing boiler is removed from a common venting system the common venting system may then be too large for the proper venting of the remaining appliances connected to it At the time of removal of an existing boiler the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation while the other appliances remaining connected to the common venting system are not in operation Au moment du retrait d une chaudi re existante les mesures suivantes doivent tre prises pour chaque appareil toujours raccord au syst me d vacuation commun et qui fonctionne alors que d autres appareils toujours raccord s au syst me d vacuation ne fonction nent pas syst me d vacuation a Seal any unused openings in the common venting system Sceller toutes les ouvertures non utilis es du sys t me d vacuation b Visually inspect the venting
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