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1. Type of pipe fitting Nominal Iron Pipe 90 Elbow Tee Gas Valve Gas Cock Size Equivalent pipe length ft 1 2 6 5 2 0 6 1 5 TA 3 5 6 9 0 8 1 9 12 4 0 8 0 0 9 2 3 27 5 2 10 3 1 2 3 0 Notes 1 For flow through branch 2 For flow at full open Figure 17 Gas Supply Piping MANUAL SHUTOFF VALVE 2 MANUAL SHUTOFF VALVE 1 E LOW PRESSURE SWITCH FROM GAS SUPPLY T i GROUND UNION r HIGH PRESSURE SWITCH i 1 1 i HIGH FIRE GAS PRESSURE ADJUSTMENT I 1 KN 16 26 amp 30 ONLY HIOM 14 REV CSD 1 TEST PORTS PRESSURE i LOW FIRE GAS PRESSURE ADJUSTMENT MODULATING GAS VALVE REGULATOR SUPPLIED BY OTHERS SEE NOTE BELOW SEDIMENT TRAP amp DRIP LEG ORNE SRE RE PILOT SHUT OFF VALVE GROUND JOINT UNION A lockup style regulator supplied by others must be installed see Figure 17 if gas pressure exceeds 14 in WC The regulator when installed as shown must be installed at a distance of at least 10 pipe diameters from the boiler main gas valve All boilers are calibrated and factory test fired at 7 in 22 WC A minimum of 2 in WC KN6 KN10 20 3 in WC KN16 KN26 KN30 and maximum of 14 in WC must be maintained to the inlet of the boiler gas train not to exceed a maximum of 1 in WC drop when firing from minim
2. 1 page 20 Boiler Operation page 21 Operating Instructions page 21 Sequence of page 24 Ignition Troubleshooting page 26 Checking amp Adjustment page 27 Diagnostics iiie iic rr teret Pridie pen page 28 MAINTENANCE 29 Pressure Switches 30 WING m page 31 Start 34 Repair Parts scere dr t cs page 36 Wallahlyuuu EE page 47 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 gas under the latest revision of ANSI Z21 13 CSA 4 9 Gas Fired Hot Water Boilers and CAN1 3 1 Industrial and Commercial Gas Fired Packaged Boilers Each unit has been constructed and hydrostatically 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
3. Sl aug SAME FUNCTION AS J12 W RS485 CABLE N n CONNECTIONS Ir Spp REED BACnet IP H E TO COMPUTER W USB CABLE MANUAL 4 SAME FUNCTION AS J11 17 W RS485 CABLE 2 IND zx 9 Sa gi PROTOCESSOR 58 RE HNET TO NEXT BOILER 2 gt SE z z lo o 8 ja 25 e 6NDy_HNET FROM PREVIOUS BOILER IN 82 206 Ez 8 MEMBER BOILER ONLY o I S 53 Sz zx 255557 HEB SHIELDED CABLE o a o 2 6 95 F amp 2 TYPICAL i3 T d 1 J12A 8 1 J12B 8 REFERENCE 1 TTTT LH L HEATNET CONTROL Bt oa HH ort SYSTEM PUMP CONTROL Jalili T lli T I2 11 amp W D 42 5819 DAMPER CONTROL zd J lil Li Li Li S DAMPER OPTIONAL STAGE LOCAL PUMP CONTROL 2 J ue LJ L CONTROL SEE TERMINATION SW S3 ALARM ndi BOILER OUTDOOR NOTES 2 3 S4 ABOVE Jj START RESET DHW PUMP CONTROL INTLK OVERRIDE CALIBRATE SWITCH BY CUSTOMER OPT FIELD WIRING ADD JUMPER TO ENABLE LOW FIRE HOLD HIOM 83 Rev 3 FACTORY WIRING INPUT O J10B 6 7 SWITCH 1 OF 2 OPTION WIRING 04 12 12 31 32 Cast Iron Condensing Boilers Installation Manual CN SERIES Figure 31 ATH Field Wiring to HeatNet Board 3 0 KN 16 KN 26 and KN 30 only The Highest priority SYSTEM FLOW PRO
4. A 3 1 CLEARANCES PER VENT MANUFACTURER S INSTRUCTIONS COMBUSTION AIR EXHAUST 5FT UL CERTIFIED 15m VENT SYSTEM MINIMUM Figure 5 Combination Direct Vent Systems 10FT 3 1 m MINIMUM TO WALL OR ADJOINING BUILDING Bus APPROVED MINIMUM NONRESTRICTIVE MAXIMUM TERMINAL SNOW LINE ROOF FLASH CLEARANCES PER VENT MANUFACTURER S INSTRUCTIONS EXHAUST ELBOW OR TEE k COMBUSTION AIR L MAXIMUM SNOW LINE 1 5 FT 0 5 m MINIMUM DISTANCE FROM INTAKE TO MAXIMUM SNOW LINE HIOM 4 REV 1 SERIES 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 6 To ensure proper operation boilers that are vented sidewall and use room air must not fire less than 2596 input Figure 6 Side Wall Venting BUILDING OVERHANG 4 FT 1 2m MAX 1 5 FT 5m MINIMUM DISTANCE FROM EXHAUST TO MAXIMUM SNOW LINE VERTICAL VENT Recommended POSITIVE PRESSURE CATEGORY IV In this configuration the boiler blower is used to push the flue products vertically to the outdoors see Figure 7 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 10FT 3 4m MINIMUM TO
5. Figure 20 Pilot Flame 1 1 2 TO 2 LONG BLUE FLAME PILOT TUBE BURNER PLAQUE 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 17 and the manual pilot shut off valve With the unit powered generate a call for heat 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 dc voltmeter 27 28 SERIES Ignition Safety To test the ignition safety shutoff device close the manual shutoff valve 1 Figure 17 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 To confirm the input of the unit follow the instructions in the INPUT RATE section b
6. 5 4 46 8 7 9 9 102 114 5 4 3 2 8 0 9 3 9 4 109 6 9 4 7 100 F 8 8 9 2 10 3 10 8 5 2 4 4 88 10 0 10 31 11 5 5 2 3 0 8 1 9 4 9 5 11 0 68 4 5 See page 36 for slide damper location on KN 6 10 20 Located on outlet flange of gas valve Figure 17 page 20 Table 12 Pressure Signal P ACTech P45 Nat Gas Firing KN6 KN10 KN20 KN16 KN26 KN30 Delta P Delta P Delta P Delta P Delta P Delta P Rate in no P4 F38 in A 245 240 ps M 74 1748 in We in d in d 10096 3 20 n a 176 3 20 n a 198 12 00 n a 240 2 60 10 00 8 00 3396 0 44 0 44 1 50 0 44 1 30 1 10 2596 0 28 0 28 0 85 0 28 0 72 0 70 2096 0 20 25 n a 0 20 30 n a 0 60 32 5 n a 0 20 0 50 0 48 Complete ACTech default settings listed on page 33 To determine signal in mm WC multiply signal pressure by 25 4 See Factory Startup sticker for LP 26 SERIES Cast Iron Condensing Boilers Installation Manual KN Series HeatNet Control Troubleshooting Firing the KN Boiler Variable Frequency KN Control Functions Ignition Contrrol en Hand Shake Drive Ignition Sequence
7. Condensate Drain Assembly Low 70 1338 1 1 1 NS Clean Out Cover 03 1830 1 1 1 NS Clean Out Cover Gasket 59 1119 1 1 1 NS Drain Pan Filter Screen 03 1826 1 1 1 14 Gas Valve DMV 02 1570 1 1 1 NS Manual Shutoff Valve 1 02 1575 2 Manual Shutoff Valve 1 1 4 02 1569 2 Manual Shutoff Valve 1 1 2 02 1578 2 NS Main Gas Orifice NG 03 2027 1 03 2023 1 03 2019 1 NS Gas Valve Orifice Gasket 59 1068 1 1 15 HeatNet Board 02 4293 1 1 1 NS 5K Resistor 58 1831 1 1 1 NS Harness J4 VFD 70 2036 1 1 1 NS Harness J5 Ctrl 70 2037 1 1 1 NS Harness Blower 70 2031 1 1 1 NS Harness J14 Transformer 70 2038 1 1 1 16 Low Gas Pressure Switch 02 4887 1 1 1 17 Air Pump 09 1518 1 1 1 18 Sight Glass 60 4280 1 1 1 19 Gasket Viewglass 59 1063 1 1 1 SERIES Cast Iron Condensing Boilers Installation Manual SERVICE AND REPLACEMENT PARTS LIST KN 6 KN 10 and KN 20 Model Size with Item Quantities Below Item Description Part KN 6 KN 10 KN 20 20 Burner 70 1216 1 70 1215 1 70 1214 1 Burner Rebuild Kit BM 1509 1 BM 1510 1 BM 1511 1 NS Combustion Chamber 45 1269 1 45 1266 1 45 1270 1 NS Low Chamber Gasket 59 1080 1 59 1065 1 59 1075 1 S dapter Pilot Orifice 56 5530 1 22 Ignitor Block Assembly 70 1345 1 1 1 NS Electrode 04 1343 2 2 2 NS Air Orifice 25 0063 2 2 2 NS Ignition Cable
8. Installation Manual N EH 57 N KN Figure 24 Exploded View Front KN 6 10 and 20 36 Cast Iron Condensing Boilers Installation Manual N EH 57 LLI N KN Figure 25 Exploded View Back KN 6 10 and 20 38 SERIES Cast Iron Condensing Boilers Installation Manual SERVICE AND REPLACEMENT PARTS LIST KN 6 KN 10 and KN 20 Model Size with Item Quantities Below Item Description Part KN 6 KN 10 KN 20 NS Jacket Assembly 70 1907 1 70 1917 1 70 1927 1 1 Blower Assembly BM 1506 1 BM 1507 1 BM 1508 1 Blower 58 1838 1 1 1 58 1844 1 2 Filter Box Gasket 59 1067 1 1 59 1072 3 3 50V Transformer 26 3211 1 1 1 NS Communication Cable RS485 40 5409 1 1 1 NS Ribbon Cable 40 5411 1 1 1 4 Pressure Switch HUBA 02 4881 1 1 1 5 Frequency Drive 58 1750 1 1 58 1752 1 6 Combustion Air Filter 59 1069 2 2 59 1071 1 NS Silicone Tape 10 5038 per foot 7 Flame Safeguard RM7895C 02 4012 1 1 1 NS Display Module 57800 02 4263 1 1 1 NS Purge Timer ST7800 02 4014 1 1 1 NS UV Amplifier R7849B 02 4015 1 1 1 8 Display Board 02 4278 1 1 1 9 Thumb Screw 57 3657 6 6 6 10 Keypad Overlay 60 5633 1 60 5632 1 60 5614 1 11 Power Switch Rocker 58 1536 1 1 1 12 Gas Train Shroud 03 1725 1 1 1 13 Condensate Drain Assembly High 70 1390 1 1 1
9. ZA EN Q lt A gt 59 SSS ESS 2 lt SKK 20 y 07247 y lt E ST d ISSN d 3 k J X g 2 SEE VIEW B 41 42 Cast Iron Condensing Boilers Installation Manual SERIES Figure 28 Gas Train Drain Pan KN 16 26 30 High Fire CO Adjustment Screw Clockwise Increase Counterclockwise Decrease o o 9 VIEW HIOM 95 REV D VIEW C HIOM 95 REV D N LL KN Cast Iron Condensing Boilers Installation Manual LU aa Figure 29 Control Panel VIEW D HIOM 95 REV D NOTE CONTROLS AND COMPONENTS MAY BE LAID OUT IN DIFFERENT LOCATIONS VIEW A HIOM 95 REV D 43 44 SERIES Cast Iron Condensing Boilers Installation Manual SERVICE AND REPLACEMENT PARTS LIST KN 16 KN 26 and KN 30 Model Size with Item Quantities Below Item Description Part KN 16 KN 26 KN 30 1 Supply Sensor 02 4284 1 1 1 2 Flow Switch 14 0203 1 1 1 3 30 psi Relief Valve 22 1809 1 22 1820 1 1 50 psi Relief Valve 22 181
10. 1 5 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 INPUT MBH HIOM 1 REV A 2000 amp Larger 1201 To 2000 amp 901 To 1200 lt 200 To 900 9 gt 8 7 56 5 53 52 gt 1 0 10 15 Horizontal Distance X Figure 3 Horizontal Air Intake and Venting for Multiple Direct Vent Systems 22777777 22777 2777777 2277777 Z 22777777 22777 Z Z EXHAUST TERMINAL BANK x 7 COMBUSTION AIR NTAKE TERMINAL Y BANK 21N 5 0cm MINIMUM BETWEEN TERMINALS NS x 7 A X 1 5FT 0 5m MINIMUM E gt 1 DISTANCE FROM INTAKE TO MAXIMUM SNOW LINE ee gt gt 27277777777 22777 HIOM 65 Cast Iron Condensing Boilers Installation Manual SERIES Figure 4 Vertical Air Intake and Venting for Direct Vent System 10FT 3 1m MINIMUM TO WALL OR ADJOINING ILDIN APPROVED BUILDING NORESTRICTIVE TERMINAL 4FT 1 2m 5 1 2 FT MINIMUM 17 MINIMUM MAXIMUM 7 SNOW f 1 5 ROOF eie BINE MINIMUM
11. 10 40 5403 1 1 1 NS Ground Cable 15 40 5404 1 1 1 23 Spark Generator Q652 26 3207 1 1 1 24 30 psi Relief Valve 22 1805 1 1 22 1809 1 50 psi Relief Valve 22 1807 1 1 22 1810 1 75 psi Relief Valve 22 1803 1 1 22 1811 1 100 psi Relief Valve 22 1808 1 1 22 1812 1 25 Blower Flange Rear Gasket 59 1059 1 1 59 1058 1 1 Goose Neck Gasket 59 1076 2 26 High Limit Aquastat Manual Reset 02 2800 1 1 1 NS 1 2 Well 02 3413 1 1 1 27 T amp P Gauge 30 amp 50 psi 20 1021 1 1 1 T amp P Gauge 75 amp 100 psi 20 1020 1 1 1 28 Low Water Cut Off 21 2061 1 1 1 NS Pilot Regulator 23 1014 1 1 1 NS Pilot Gas Valve V4046C 02 1749 1 1 1 29 10K Sensor 02 4283 2 2 2 NS 2 1 2 Well 02 4285 2 2 2 34 Supply Nipple 70 1347 1 1 1 35 5 Flue Adapter 56 3347 1 6 Flue Adapter 56 3349 1 8 Flue Adapter 156 0006 01 1 9 Flue Adapter 56 3348 1 36 Pressure Switch NS2 02 5208 3 3 3 37 Ignition Cover 70 1336 1 1 1 NS Rating Label 42 2997 1 1 1 NS Toggle Switch 58 1535 1 1 1 39 Cast Iron Condensing Boilers Installation Manual N EH 57 LLI N KN Figure 26 KN 16 26 and 30 M 2 HIOM 95 REV D HIOM 95 REV D N _ KN Cast Iron Condensing Boilers Installation Manual LL gt b T Yn P D v n n gt gt gt gt v v NmmPYr F Ve b RP L O T F D n m O o N Figure 27 KN 16 26 and 30
12. Boilers Installation Manual MACODE 3 Commonwealth of Massachusetts Installation Requirements a For all side wall horizontally vented gas fueled equipment installed in every dwelling building or structure used in whole or in part for residential purposes including those owned or operated by the commonwealth and where the side wall exhaust vent termination is less than seven 7 feet above finished grade in the area of the venting including but not limited to decks and porches the following requirements shall be satisfied 1 INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas fueled equipment the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back up is installed on the floor level where the gas equipment is to be installed In addition the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling building or structure served by the side wall horizontal vented gas fueled equipment It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors a In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic the hard wire
13. DC Bus Voltage 53 Motor Voltage N O 54 Load a 55 0 10 VDC Input AY 56 4 20 mA Input 57 Strip Status 58 Keypad Status These values can be adjusted in the field for precision tuning 33 34 Cast Iron Condensing Boilers Installation Manual SERIES START UP REPORT HydroTherm DATE JOB NAME TECHNICIAN LOCATION COMPANY MODEL PHONE NUMBER SERIAL PRE STARTUP CHECK LIST Q NO VISIBLE DAMAGE TO UNIT INLET AIR FILTER INSTALLED AND CLEAN Q PIPING PROPERLY CONNECTED 1 PROPER SERVICE CLEARANCES PROVIDED 1 BOILER CIRCULATOR WIRED PUMP RUNNING HEAT EXCHANGER FULL 1 VENT STACK CONNECTED Q GAS LINES PURGED NO LEAKS NO MISSING TEST PLUGS BOILER STARTUP SEQUENCE Note Locate the AA terminals and minimum hold switch in the bottom right of the electrical panel on the main HeatNet board Also locate the manometer test manifold in the bottom of the electrical panel 1 Disable any external call for heat and toggle the remote local switch to REMOTE Toggle the LOW FIRE switch to cycle the boiler then hold at trial for pilot ignition Set pressure to 2 5 3 5 WC flame signal should read 5 0 VDC Release boiler to main flame trial for ignition Checkfor stable flame Record combustion and Delta P at minimum firing rate Jumper the AA terminals to force 10096 input Record combustion and Delta P at high firing rate Remove the AA
14. Fire 40 F 7 4 7 8 87 9 2 7 6 7 0 7 4 8 6 8 7 10 1 7 6 5 6 6 7 8 0 7 7 9 4 8 6 6 9 30 F 7 5 7 9 8 8 9 3 7 5 6 8 7 5 8 7 8 8 10 2 7 5 5 4 6 8 8 1 7 9 95 8 5 6 7 20 F 7 6 8 0 8 9 9 4 7 4 6 6 7 6 8 8 8 9 10 3 7 4 5 2 6 9 8 2 8 0 9 6 8 5 6 5 10 F 7 7 8 1 9 0 9 5 7 2 6 5 7 7 8 9 9 0 110 4 7 2 5 0 7 0 8 3 8 2 9 7 8 4 6 4 O F 7 8 8 2 9 2 96 7 0 6 4 7 8 9 0 9 2 110 5 7 0 4 8 7 1 8 4 8 3 9 8 8 4 62 10 F 7 9 8 3 9 3 9 7 6 8 6 2 7 9 9 1 9 3 106 6 8 4 6 7 2 8 5 8 4 9 4 8 3 6 1 20 F 8 0 8 4 9 4 9 8 6 6 60 8 0 9 2 9 4 107 6 6 4 4 7 3 8 6 8 5 10 1 8 1 5 9 30 F 8 1 8 5 9 5 9 9 6 5 5 8 8 1 9 3 9 5 108 6 5 42 7 4 8 7 8 7 10 2 7 9 5 7 40 F 8 2 8 6 9 6 10 1 6 4 5 6 8 2 9 4 9 6 10 9 6 4 4 1 7 5 8 8 8 8 103 7 8 5 5 50 F 8 3 8 7 9 7 10 2 6 2 5 4 8 3 9 5 9 7 11 0 6 2 4 0 7 6 8 9 8 9 10 5 7 6 5 3 60 F 8 4 8 8 9 8 10 3 6 0 52 8 4 9 6 9 8 11 1 6 0 3 8 7 7 9 0 9 0 10 6 7 4 52 70 F 8 5 8 9 9 9 10 5 5 8 5 0 8 5 9 7 9 9 11 2 5 8 3 6 7 8 9 1 9 2 10 7 7 2 5 0 80 F 8 6 9 0 10 1 10 6 56 48 8 6 9 8 110 1 11 3 5 6 3 4 79 9 2 9 3 10 8 7 1 48 90 F 8 7 9 1 10 2 10 7
15. Honeywell 57800 DISPLAY INPUTS STANDBY Hr IS 3 Heat Demand 4 4 20ma 5 T1 T4 Operate Blower Motor 0 J13 CIRC Start Circulator C Interlocks OK gt J5 J11A J11B Setpoint 1 2 Are we below the Temp Band Peal Band NO YES fire the boiler Close the Last J5 Pin 10 DISPLAY limit in the Limit LIMITS LIMITS HEATING String to Ignition Control Z TERM 6 LIMITS J5 Pin 3 NO ave e N BLOWER Operate Blower J4 Pins 4 amp 8 received the BLOWER Send 120 VAC 0 BLOWER BLOWER signal signal MOTOR If Yes do not operate blower MAIN VALVE greater than 7 VAC 5 J4 Pins 4 amp 8 Operate Blower Motor 55 PRE PURGE DISPLAY PRE PURGE 8 J5 Pin 2 v PILOT After 10 Seconds PILOT signal PILOT send PILOT signal YES J4 Pins 4 amp 8 Operate Blower Motor 32 4 lt DISPLAY PILOT YES JS Pin 1 After 10 S d er econds MAIN signal MAIN MAIN send MAIN VALVE signal MES TERM 9 MAIN Pins 158 1 Minimum fire rate a E ire 2 Hold for x secs pes odulate to DISPLAY 3 Modulate to temp aintain temp RUN 25 SERIES 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 allow the electrodes to cool Check and adjust the spark gap as shown i
16. Low Water Gas Pressure High amp Low Spare for user or Factory ES 2102 CIC mm a e lee 2 21348 1 aves ead xs ap E Remote 120 vac Operator t Jumper if Not Used USB and Flashdrive Ports Used by HeatNet Pro and updating firmware Low Fire Hold Fires the boiler at the minimum rate while in Lo Calibrate This functions exactly x m as the T1 input Calibrate Allows adjustment of ES the Minimum Fire Maximum Fire and Pilot Ignition settings m he gt Combustion proving switch Stage Control from Combustion Air Damper Close to run boiler at High Fire Damper Control DHW Pump or Power Open Power Close Valve Local Pump or Power Open Power Close Valve SERIES Cast Iron Condensing Boilers Installation Manual AC TECH DEFAULT SETTINGS FOR HYDROTHERM KN SERIES BOILERS PARAMETER KN 6 KN 10 KN 20 KN 16 26 30 NAME NG LPG NG LPG NG LPG No VED 01 Line Voltage 01 01 01 01 01 01 Lis Gries 02 Carrier Frequency 03 03 03 03 03 03 next page 03 Start Method 06 06 06 06 06 06 tor blower 04 Stop Method 01 01 01 01 01 01 ndine card 05 Standard Speed Sourc
17. WALL OR ADJOINING APPROVED BUILDING NORESTRICTIVE TERMINAL MAXIMUM SNOW ROOF l LINE PERSE MINIMUM 2 NI AN Z A Cast Iron Condensing Boilers Installation Manual 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 HORIZONTAL DIRECT VENT SYSTEMS section must also be followed PITCH PIPE DOWN TOWARDS BOILER 1 4 IN PER FT 20 mm m OF RUN TO ALLOW FOR CONDENSATE DRAINAGE HIOM 5 REV 1 Figure 7 Vertical Positive Pressure Venting HIOM 6 REV 1 CLEARANCES PER VENT MANUFACTURER S INSTRUCTIONS EXHAUST UL CERTIFIED VENT SYSTEM SERIES VERTICAL VENT Optional NEGATIVE PRESSURE CATEGORY The KN is listed as a Category Il appliance when vented vertically into a listed metal AL294C S S chimney system Figure 8 The chimney system must provide a negative pressure of 0 02 to 0 10 in 0 51 to 5 08 mm WC at the boiler flue collar with the unit running When using a listed metal chimney system the chimney system manufacturer s instructions must be followed Multiple boiler vent systems must be designed and verified by a qualified professional and stack manufacturer The vent system must prevent backflow of exhaust gas through idle boilers When more than one appliance is connected to the same
18. 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 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 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 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 Combust
19. at boiler operating conditions A minimum system pressure of 25 psig 172 kPa fill pressure is required at boiler operating conditions on glycol mixtures within a closed loop Cleaning Flushing System Prior to commissioning the boiler s the piping system must be cleaned and flushed to prevent contaminants from settling back into the boiler and fouling the heat exchanger Isolate the boiler from the system prior to the cleaning process Fill the system with water add the cleaning solution and circulate per the chemical supplier s instructions until the system TDS is within 1096 of the city water TDS Add the corrosion inhibitor to the system and follow the chemical supplier s instructions Boiler Piping Connections The supply and return connections should be sized to suit the system see Table 7 Table 7 Supply amp Return Pipe Sizing Model Supply Return Size Size Size 600 3 NPT 3 NPT 1000 3 NPT 3 NPT 1600 3 NPT 3 NPT 2000 3 NPT 3 NPT 2600 4 NPT 4 NPT 3000 4 NPT 4 NPT Cast Iron Condensing Boilers Installation Manual Water Treatment This boiler was designed to operate in a closed loop heating system Water treatment is required when fill or make up water contains dissolved solids greater than 200 ppm or if PH level is not within the 6 5 11 range For systems requiring glycol for freeze protection use a glycol water mix that prevents foaming The air entrapment within thi
20. be vented the following ways 1 Direct Vent individual venting only page 8 amp 9 Positive Pressure Category IV uses a vent system certified to UL 1738 for installations in the United States ULC 5636 for installations in Canada Combustion air is piped from the outdoors to the blower inlet 2 Side Wall Vent individual venting only page 10 Positive Pressure Category IV uses a stainless steel vent system certified to UL 1738 for installations in the United States ULC S636 for installations in Canada Combustion air is obtained from the space in which the unit is installed To ensure proper operation boilers that are sidewall vented and use room air must not be fired less than 2596 input 3 Vertical Vent individual venting only page 10 Positive Pressure Category IV uses a stainless steel vent system certified to UL 1738 for installations in the United States ULC 5636 for installations in Canada Combustion air is obtained from the space in which the unit is installed 4 Vertical Vent individual venting only page 11 Negative Pressure Category uses an approved S S UL 1738 metal chimney system Combustion air is obtained from the space in which the unit is installed 5 Common Vent page 7 Negative Pressure Category Il Positive Pressure Category IV KN 16 26 30 only uses a stainless steel vent system certified to UL 1738 for installations in the United States ULC 5636 for installations
21. chimney system the system must be large enough to safely vent the combined output of all of the appliances Table 5 lists the equivalent breeching and chimney sizes required for a single boiler installation 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 appliances to this flue Doing so can result in excessive levels of carbon monoxide which can cause severe personal injury or death Table 5 Equivalent Breeching amp Chimney Size Negative Pressure Single Boiler Model Breech amp Flue Diameter Size in mm 600 8 204 1000 12 305 1600 14 356 2000 14 356 2600 14 356 3000 14 356 NOTICE 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 Cast Iron Condensing Boilers Installation Manual The vent system should be sloped up toward the chimney at a minimum rate of 1 4 in ft 2 Never install a vent pipe o
22. elnput 1 The blower operates at minimum ignition setting See the calibration section in the KN Series Control IOM to enter the calibration menus 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 setting for 3 seconds then operates at demand input See the calibration section in the KN Series Control IOM to enter the calibration menus 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 SERIES Cast Iron Condensing Boilers Installation Manual Table 11 Combustion Settings KN 6 10 20 Series KN 6 10 20 Series KN 16 26 30 Series G amp D Mat Mesh Burners Bekaert Burner 2010 Bekaert Burner 2010 prior to 2010 w Air Orifice Slide Trim w Gas Orifice Slide Trim CO CO CO NG LPG cd NG LPG NG LPG Temp Low High Low High Low High Low High Low High Low High Low High Low High Low High Fire Fire Fire Fire Fire Fire Fire Fire Fire Fire Fire Fire Fire Fire Fire Fire Fire
23. fire or explosion may result causing property 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 Donottry 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 phone outside of the building 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 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 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 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 gas depuis un voisin Suivez les intructions du fournisseur 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 q
24. 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 LOCKOUT FLOW SWITCH Indicates that the water flow switch is open with a call for heat LWCO LOCKOUT Indicates low or no water in the boiler SERIES MAINTENANCE 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 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 corrosi
25. tank Install sensor with heat sensing compound m Thermal expansion tank may be required check local codes e Hot water tank should be equipped with a combination temperature and pressure relief valve Valve shall discharge to a safe place with an air gap Refer to local codes gt Code requires 1 8 hole in check valves to compensate for thermal expansion Boiler and pump purging required Air must be purged from 3 way valve after the boiler is filled Use purge valves provided Purge valve may be located on pump flange On multiple boiler installations the flow switch may fail due to trapped air See manual for procedure SUPPLY o Contractor shall verify with authority having jurisdiction for the requirements of an acid neutralization kit Notice These drawings show suggested piping configuration valving and are diagrammatic Check with local codes and ordinances for specific requirements Bronze MAKE UP Pump FLOW Circulator Return G N NIN Pump Gate Valve Check Valve Backflow Prevention Temperature amp Pressure Device Pressure Relief Valve COLD WATER MAKE UP NOTE Not all system valves may be shown Consult local codes for additional system components which may be necessary HIOM 12 REV 3 Vacuum Relief Thermometer Expansion Heat Net Relief Valve Valve Tank S
26. 0 1 22 1821 1 1 75 psi Relief Valve 22 1811 1 22 1822 1 1 100 psi Relief Valve 22 1812 1 22 1823 1 1 4 Air Vent 60 4257 1 1 1 NS Sight Glass 60 4280 1 1 1 Gasket Viewglass 59 1063 1 1 1 5 High Limit Aquastat Auto Reset 02 3204 1 1 Well 1 2 02 3413 1 1 6 High Limit Aquastat Manual Reset 02 2800 1 1 1 Well 1 2 02 3413 1 1 1 7 Gauge 30 amp 50 psi 20 1021 1 1 1 T amp P Gauge 75 amp 100 psi 20 1020 1 1 1 8 Return Sensor 02 4284 1 1 1 9 Filter Box Cover 75 00222 001 1 1 1 10 Gasket Filter Box Cover 06 00013 001 1 1 1 11 Air Filter 20 00003 001 1 1 1 12 Filter Box Assembly 70 1487 1 NS Gasket Blower Filter Box 06 00010 001 1 1 1 NS 1 4 Aluminum Tubing 54 1601 per foot 13 UV Flame Sensor C7027 02 5206 1 1 1 14 Block Sections Consult Tech Dept model and serial number 15 Jacket Assembly Consult Customer Service model and serial number required NS Gasket Blower Adapter Upper Cover 06 00017 001 1 06 00009 001 1 1 5 Flue Adapter 09 00002 002 1 09 00002 001 1 1 16 Blower 12 00002 001 1 12 00003 001 1 1 5 Gasket Blower Blower Adapter 06 00008 001 1 1 1 17 Blower Adapter Weldment 74 00232 001 1 74 00210 001 1 1 18 Upper Cover Assembly 75 00206 004 1 75 00206 002 1 75 00206 001 1 18a Burner Assembly 75 00205 004 1 72 00205 002 1 75 00205 001 1 NS Gasket Burner Ceramic Chamber 06 00002 004 1 1 1 18b Combustion Chamber 75 00244 004 1 75 00244 002 1 75 00244 001 1 19 Drain Pan Assembly 75 00202 004 1 75 00202 002
27. 1 75 00202 001 1 NS Gasket Drain Pan Cleanout Cover 06 00001 001 1 1 1 NS RTV Red Sealant 10 Oz Tube 10 6635 1 1 1 NS Pilot Assembly 75 00207 002 1 70 1488 1 1 NS Pilot Orifice 25 0061 1 1 1 NS Adapter Pilot Orifice 56 5530 1 10 00101 001 1 1 SERIES Cast Iron Condensing Boilers Installation Manual SERVICE AND REPLACEMENT PARTS LIST KN 16 KN 26 and KN 30 Model Size with Item Quantities Below Item Description Part KN 16 KN 26 KN 30 NS Elbow Pilot 60 4256 1 1 1 NS Pilot Tube 10 00105 002 1 10 00105 001 1 1 21 Ignitor Block Assembly 70 1345 1 1 1 21a Electrode 04 1343 1 1 1 NS Air Orifice 25 0063 1 1 1 NS Ignition Cable 24 16 00004 001 1 1 1 NS Ground Cable 15 16 00008 001 1 1 1 22 Condensate Drain Assembly High 70 1390 1 1 1 Condensate Drain Assembly Low 70 1338 1 23 Manual Shutoff Valve 1 1 2 02 1578 1 1 1 24 Regulator RV12LT 23 1014 1 1 1 25 Pilot Gas Valve V4046C 02 1749 1 1 1 26 1 8 Gas Cock 23 1016 1 1 1 27 Manual Shutoff Valve 1 1 2 02 1578 1 1 1 28 Gas Valve MBC 11 00002 001 1 1 1 28 Low Gas Pressure Switch 02 4887 1 1 1 28b High Gas Pressure Switch 02 4886 1 1 30 Bolt Assembly 15 00203 001 14 20 34 31 Clean Out Cover 74 00202 001 1 1 1 32 Cle
28. D WATER MAKE UP x Pressure Aquastat Reducing Valve Expansion Tank 15 16 Cast Iron Condensing Boilers Installation Manual SERIES Figure 11 Typical Multiple Boiler Reverse Return Piping RECOMMENDED Careful consideration as to minimum boiler and system water flow rates must be taken Please consult our local manufactures representative for assistance AIR SEPARATOR ALTERNATE LOCATION SYSTEM f 4 RETURN L po AIR SEPARATOR TYPICAL LOCATION 79 X Y Y y WY WY SYSTEM COLD WATER SUPPLY MAKE UP HIOM 11 REV 4 NOTE Not all system valves may be shown Consult local codes for additional system components which may be necessary For HeatNet operation a sensor is required and installed at a minimum of 12 from primary loop tee Figure 12 Typical Single Boiler Primary Secondary Piping MINIMUM 3X PIPE DIAMETERS MAXIMUM 10X PIPE DIAMETERS Y gt SYSTEM RETURN lt A AIR SEPARATOR BETWEEN CENTERS ALTERNATE LOCATION SYSTEM SUPPLY g AIR SEPARATOR TYPICAL LOCATION 2 DHNEN HIOM 9 REV 4 COLD WATER MAKE UP NOTE Not all system valves may be shown Consult local codes for additional system components which may be necessary For HeatNet operation a sensor is required and installed at a minimum of 12 from
29. 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 3 Please refer to the back of this manual for required regulations 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 SERIES 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 RATINGS amp CAPACITIES Before installing the KN boiler check 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 vent system LOCATION This boiler is sui
30. IOMKN 2 1112 42 9533 HydroTherm CAUTION Boiler Manual Installation and Operation Instructions ADI CERTIFIED www ahridirectory org 0 CERTIFIED MEA 444 05 E MASS Plumbers G1 06 04 28 This manual is intended only for use by a qualified heating installer technician Read and follow this manual all supplements and related instructional information provided with the boiler Install start and service the boiler only in the sequence and methods given in these instructions Failure to do so can result in severe personal injury death or substantial property damage Do not use the boiler during construction Construction dust and particulate particularly drywall dust will cause contamination of the burner resulting in possible severe personal injury death or substantial property damage The boiler can only be operated with a dust free air supply Follow the instruction manual procedures to duct air to the boiler air intake Ifthe boiler has been contaminated by operation with contaminated air follow the instruction manual guidelines to clean repair or replace the boiler if necessary Affix these instructions near to the boiler water heater Instruct the building owner to retain the instructions for future use by a qualified service technician and to follow all guidelines in the User s Information Manual 10 12 Copyright 2010 Hydrotherm SERIES If the information in this manual is not followed exactly a
31. N Improper piping of this boiler will void the manufacturer s warranty and can cause boiler failure resulting in flooding and extensive property damage 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 9 Mount on rear section or vertically on supply nipple cAUTION Never install any type of valve between 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 optional on KN 6 10 and 20 standard on KN 16 26 and 30 is wired to prevent the boiler from firing unless there s adequate water flow through the unit If using the optional flow switch failure to maintain the minimum flow rates listed in Table 6 at the boiler outlet will prevent the flow switch from closing If a minimum flow rate cannot be maintained at the boiler outlet the flow switch will have to be relocated in the system Cast Iron Condensing Boilers Installation Manual Table 6 Water Flow Rates AT Across GPM Heat Exchanger Min Max Min Max KN 6 10 100 20 F 100 F KN 10 15 150 20 F 100 F KN 16 24 240 20 F 100 F KN 20 30 300 20 F 100 F KN 26 38 380 20 F 100 F KN 30 45 450 20 F 100 F Min Max At corre
32. OM 18 YELLOW FLOATING FLAME Cast Iron Condensing Boilers Installation Manual SERIES Figure 22 KN 6 10 and 20 Pressure Switches AIR FILTER BOX AT BACK OF IGNITOR BLOCK ASSEMBLY UV SCANNER SWITCH HUBA PRESSURE E PS1 PS2 53 FLUE BLOCKED REAR LEGEND CONNECTION AIR TUBE PS2 POSITIVE PRESSURE NEGATIVE PRESSURE TAP REAR TEST PORTS PRESSURE SWITCH BLOCKED FLUE A s TEST PORTS CAPPED PRESSURE SWITCH BLOCKED INLET GAS VALVE ASSEMBLY Figure 23 KN 16 26 and 30 Pressure Switches TO PILOT gt pt 4 FILTER BOX HOUSING PORT OPEN TO FILTER BOX COMPRESSION FITTINGS BARB FITTINGS IGNITOR BLOCK ASSEMBLY UV SCANNER gt PS1 TEST PORTS HUBA SWITCH CAPPED BLOWER PROVEN SWITCH gt REAR P1 SWITCH FOR RONT P2 FRONT FRONT P PS2 PRESSURE SWITCH COMBUSTION BLOCKED FLUE PILOT GAS TRAIN PS3 PRESSURE SWITCH BLOCKED INLET LEGEND amme FLEXIBLE PLASTIC TUBING ALUMINUM TUBING POSITIVE PRESSURE GAS VALVE ASSEMBLY L 2 NEGATIVE PRESSURE TAP SERIES Cast Iron Condensing Boilers Installation Manual Figure 30 ATH Fi
33. R OPTION instructions under the COMBUSTION AIR amp VENTILATION SECTION must be followed Horizontal Direct Vent Systems Figures 2 amp 3 The vent materials used in positive pressure vent systems must be certified to UL 1738 for installations in the United States ULC S636 for installations in Canada 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 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 7 5m they must be supported at 3 ft 0 98 m intervals with overhead hangers 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 212 C Cast Iron Condensing Boilers Installation Manual 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 7 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 above adjac
34. Sensor Relief Valve SERIES CONDENSATE PIPING The condensate trap provided with the boiler must be attached to the bottom pan and piped to a suitable floor drain consult local code or condensate pump If a condensate neutralization device is required by local code it must be positioned prior to boiler room drain Fill the condensate trap with water check and maintain water level in trap during operation prior to start up Figure 16 KN Series Condensate Drain HIOM 81 REV D Cast Iron Condensing Boilers Installation Manual GAS SUPPLY PIPING 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 8 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 8 should be used in conjunction with Table 9 to ensure that the gas supply piping has the capaci
35. Tech Drive to scroll to P46 Press Mode to view the entry use the Arrow Keys to adjust the value to achieve the required combustion CO2 O2 Table 11 and pressure delta p Table 12 at high fire The default values are listed below on Table 12 The high fire trim adjustment is located inside the air box This shutter allows for a 2 2 adjustment for high fire only When complete press the mode key once to clamp the desired setting When all adjustments are finished remove jumper Allow the boiler to settle into min input and observe combustion readings to ensure the boiler is operating correctly Make any required adjustments When complete disable the low fire hold switch 23 24 SERIES 26 Boiler allows for many modes of operation and control methods Reference the Model KN Series Control IOM for instruction 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 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 u
36. VE MISSISSAUGA ONT 1155 114 905 672 2991 FAX 905 672 2883 www hydrothermkn com 47 HydroTherm MESTEK COMPANY IN UNITED STATES 260 NORTH ELM ST WESTFIELD 01085 413 564 5515 FAX 413 568 9613 CANADA 7555 TRANMERE DRIVE MISSISSAUGA ONT 1155 1L4 905 672 2991 FAX 905 672 2883 www hydrothermkn com
37. an Out Cover Gasket 06 00001 001 1 1 1 33 Drain Pan Weldment 74 00201 004 1 74 00201 002 1 74 00201 001 1 34 Drain Pan Filter Screen 03 00263 001 1 1 03 1826 1 39 Low Water Cutoff 21 2061 1 1 1 40 Toggle Switch 58 1535 2 2 2 43 Display Board 02 4278 1 1 1 44 Power Switch Rocker 58 1536 1 1 1 45 Hidden Panel Weldment 70 1480 1 1 1 46 Front Control Panel Weldment 70 1486 1 1 1 48 Front Jacket Panel 74 00212 1 1 1 49 Spark Generator Q652 26 3207 1 1 1 50 Gas Support Bracket Right 74002134 1 1 1 5 Gas Support Bracket Left 74 00214 001 1 1 1 52 Gas Train Shroud 74 00221 1 1 1 53 Front Control Panel Door 03 00240 001 1 1 1 54 Front Panel Left 74002164 1 1 1 55 Front Panel Right 74 00215 001 1 1 1 57 HeatNet Board 40 00751 1 1 1 NS Ribbon Cable 40 00259 001 1 1 1 59 50VA Transformer 26 3211 1 1 1 60 250VA Transformer 15 00001 001 1 1 61 Blower Overload Relay 15 00101 001 1 1 1 62 Contactor 2 HP 15 00102 001 2 2 2 5 Pump Fuse 2 HP 48 00602 002 1 3 3 63 Flame Safeguard RM7895C 02 4012 1 1 1 NS Purge Timer ST7800 02 4014 1 1 1 NS UV Amplifier R7849B 02 4015 1 1 1 64 Air Pressure Switch NS2 02 5208 1 1 1 65 Air Pressure Switch NS2 14 00305 001 1 1 1 66 Pressure Switch HUBA 02 4881 1 1 1 Bracket Pressure Switch 14 00302 001 1 1 1 67 Air Pump 09 1518 1 1 1 NS HeatNet Overlay 82 00403 001 1 1 1 NS Front Panel Overlay 82 00405 004 1 1 1 NS Rating Label 42 2997 1 1 1 45 46 SERIES NOTICE Cast Iron Condensing
38. d carbon monoxide detector with alarm and battery back up may be installed on the next adjacent floor level b Inthe eventthat the requirements of this subdivision can not be met at the time of completion of installation the owner shall have a period of thirty 30 days to comply with the above requirements provided however that during said thirty 30 day period a battery operated carbon monoxide detector with an alarm shall be installed 2 APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI UL 2034 listed and IAS certified 3 SIGNAGE A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS 4 INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless upon inspection the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5 08 2 a 1 through 4 Improper venting can result in excessive levels of carbon monoxide which can cause severe p
39. e 03 03 03 03 03 03 adjustment 06 Relay Output 03 03 03 03 03 03 10 TB 13A Function Select 01 01 01 01 01 01 11 TB 13B Function Select 01 01 01 01 01 01 12 TB 13E Input Output Other Functions 01 01 01 01 01 01 14 Control 01 01 01 01 01 01 16 Units Editing 02 02 02 02 02 02 17 Rotation 01 01 01 01 01 01 19 Acceleration Time 20 0 20 0 20 0 20 0 20 0 20 0 20 Deceleration Time 20 0 20 0 20 0 20 0 20 0 20 0 21 DC Brake Time 0 0 0 0 0 0 22 DC Brake Voltage 0 0 0 0 0 0 23 Minimum Frequency 0 0 0 0 0 0 24 Maximum Frequency 150 150 150 150 180 180 25 Current Limit 125 125 125 125 125 125 26 Motor Overload 80 0 80 0 80 0 80 0 80 0 80 0 27 Base Frequency 180 180 180 180 180 180 28 Fixed Boost 1 0 1 0 1 0 1 0 1 0 1 0 29 Accel Boost 0 0 0 0 0 0 30 Slip Compensation 0 0 0 0 0 0 31 0 0 0 0 0 0 32 0 0 0 0 0 0 33 0 0 0 0 0 0 34 Preset Speeds 0 0 0 0 0 0 35 0 0 0 0 0 0 36 0 0 0 0 0 0 37 0 0 0 0 0 0 38 Skip Bandwidth 0 0 0 0 0 0 39 Speed Scaling 0 0 0 0 0 0 41 Fault Delay 0 5 0 5 0 5 0 5 0 5 0 5 42 Accel Decel 2 20 0 20 0 20 0 200 20 0 20 0 43 SPD At Minimum Offset 1 9 1 9 1 9 1 9 1 9 1 9 44 Password 523 523 523 523 523 523 45 Speed at Min Signal 25 0 25 0 30 0 30 0 32 5 33 8 46 Speed at Max Signal 176 185 198 193 240 216 47 Clear History 01 01 01 01 01 01 48 Program Selection 01 01 01 01 01 01 50 Fault History 51 Software Code 52 _
40. e low fire switch allowing the boiler to stop Cast Iron Condensing Boilers Installation Manual UP BUTTON VARIABLE FREQUENCY DRIVE DOWN BUTTON 24 VAC TRANSFOMER Figure 18 Control Panel MAIN DISPLAY HONEYWELL 7800 HET NET CONTROL BOARD HONEYWELL RESET BUTTON OPTIONAL BACNET LON WORKS CONTROL ENTER BUTTON BACK BUTTON e Le a V MODBUS COMMUNICATION BOARD ON OFF SWITCH 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 17 19 Switch the Honeywell 7800 back to run 20 Create a minimum 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 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 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
41. e trim adjustment is located on the outlet flange Figure 17 of the gas valve When complete press the select key once to clamp the desired setting When all adjustments are finished place the S2 switch back to the off position Allow the boiler to settle into min input and observe combustion readings to ensure the boiler is operating correctly Make required adjustments When complete disable the low fire hold switch Follow the instructions in the HeatNet Control manual to allow adjustments required for high altitude installations KN6 KN10 amp KN20 a b Follow the instructions in the HeatNet Control manual to calibrate the required input delta p for high altitude installations The maximum firing rate value in the HeatNet control is factory set at 9096 At this setting for sea level applications and with typical vent lengths the boiler will be at rate DO NOT increase above 9096 unless needed for high altitude installations For sea level installations only the ACTech drive can be used to trim high fire input as follows Jumper the AA terminals the boiler input will rise to its maximum input Run 100 see Figure 30 Press the Mode button on the AC Tech Drive The drive will now require a password Use the Arrow Keys on the AC Tech Drive to enter the password value of 523 then press Mode The parameters of the drive will be accessible at this point Use the Arrow Keys on the AC
42. ed by the manufacturer 1 The referenced special venting system instructions shall be included with the appliance or equipment installation instructions and 2 The special venting systems shall be Product Approved by the Board and the instructions for that system shall include a parts list and detailed installation instructions e A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equip ment all venting instructions all parts lists for venting instructions and or all venting design instructions shall remain with the appliance or equipment at the completion of the installation Improper venting can result in excessive levels of carbon monoxide which can cause severe personal injury or death Cast Iron Condensing Boilers Installation Manual SERIES Hydrotherm KN Series Water Boiler Limited Warranty One Year Warranty The Manufacturer warrants to the original owner at the original installation site that the KN series modulating water boiler Product will be free from defects in material and workmanship for one 1 year from the date of installation or eighteen 18 months from the date of shipment from the factory which ever comes first If upon examination by the manufacturer the product is shown to have a defect in material or workmanship during the warranty period the manufacturer will repair or replace at its option that part of the product which i
43. eld Wiring To HeatNet Board 2 0 KN 6 KN 10 and KN 20 only gt WIRING SHOWN AS BET amp REFERENCE ONLY Z OUTSIDE AIR TEMP SENSOR 1 r 5 Os HIGH OPT amp LOW VFD INTERLOCK GAS PRESSURE SW l rr SYSTEM TEMP SENSOR OPT 58 N F Z DHW TEMP SENSOR OPT EN LWCO LOCAL WATER N l F BLOWER MODULATION Er PROVE SW FLOW SW 1 IT SEE NOTE 4 WE Lt uv sensor lI I E PBLYOPY PR O IR PR GW GW GW n 1d Al ze H HH CONTROL 5 Lili tt i 0202255222200 sole 1 J11A 8 1 Ji1B 8 1 J10A 8 l 1 8 z e lt 2 xu s zz zs lt a Boo 5 y H 49 9 55 5 2 S FOR 0 10 INPUT 2 uo c z E 04 X 4 le ES zu 2 lt eG 5 xS Eli ro tzo E el J108 6 7 x x Eo TNT MOVE JUMPER E gt 6x JP3 TO PINS 1 2 c N s SHIELDED CABLE OR TB gk z TWISTED PAIR WIRE PRON MASTER ES 9 JO 800 BACnet MSTP CONTROL ONLY TB1 R a MANAGEMENT W2zgi MODBUS TO BLDG MANAGEMENT SYSTEM 12 N SYSTEM 1 w SHLD CABLE OR TWISTED PAIR WIRE w Iz FOR OTHER a TBi o 2 oR
44. elow 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 18 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 function properly Test in accordance with the manufacturer s instructions included with the device s Cast Iron Condensing Boilers Installation Manual DIAGNOSTICS The KN has a display that indicates the sequence of operation Figure 18 The display will also list faults should the unit fail to operate An explanation of each fault is listed below STANDBY KN 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
45. ensor 17 18 Cast Iron Condensing Boilers Installation Manual SERIES Figure 15 Typical Multiple Boiler with Indirect Storage Tank Piping NOTES When using intermittent pump and pump delay locate HeatNet sensor with well in lower 1 3 of tank Install sensor with heat sensing compound m Thermal expansion tank may be required check local codes COLD WATER MAKE UP e Common piping must be sized for maximum combined heater flow A Hot water tank should be equipped with a combination temperature e and pressure relief valve Valve shall discharge to a safe place with an air gap Refer to local codes MA Code requires 1 8 hole in check valves to compensate for thermal expansion 9 Contractor shall verify with authority having jurisdiction for the requirements of an acid neutralization kit Notice These drawings show suggested piping configuration valving and are diagrammatic Check with local codes and ordinances for specific requirements COLD WATER MAKE UP FILL Bronze gt Pump Circulator Return SUPPLY NOTE Not all system valves may be shown Consult local codes for additional system components which may be necessary HIOM 13 REV 3 idit O NN Pump Gate Valve Check Valve Backflow Prevention Temperature amp Pressure Vacuum Relief Thermometer Expansion Heat Net Device Pressure Relief Valve Valve Tank
46. ent 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 1 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 When running horizontal combustion air and venting for single or multiple units exhaust and combustion air terminals must be installed on the same plane outside wall in order to prevent pressure differences due to prevailing winds In cold climates double wall or insulated inlet pipe recommended to prevent condensation Vertical Direct Vent Systems see Figure 4 The vent materials used in positive pressure vent systems must be certified to UL 1738 for installations in the United States ULC S636 for installations in Canada If any part of a single wall metal vent system passes through an unheated space it must be insulated with insulation rated for 400 204 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 4 In addition the vent system must conform to the dimensions shown in Figure 4 The penetration point in the roof must be properly flashed and sealed The vent system must be gas tight All seams and jo
47. eral Piping Requirements The KN boiler can be use in combination with an indirect tank to provide hot water for domestic use Piping and components 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 Cast Iron Condensing Boilers Installation Manual 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 14 amp 15 Thermostatic Mixing Valve Water Above 140 F 60 C Water be stored a temperatures above 140 60 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 60 C will provide an increased quantity of tempered water and help prevent the growth of water born bacteria Figure 14 Typical Single Boiler with Indirect Storage Tank Piping NOTES When using intermittent pump and pump delay locate HeatNet sensor with well in lower 1 3 of
48. ersonal injury or death In the Commonwealth of Massachusetts the installation must be performed by a licensed plumber or gas fitter b Exemptions The following equipment is exempt from 248 CMR 5 08 2 a 1 through 4 1 The equipment listed in Chapter 10 entitled Equipment Not Required To Be Vented in the most current edition of NFPA 54 as adopted by the Board and 2 Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling building or structure used in whole or in part for residential purposes c MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM PROVIDED When the manufacturer of Product Approved side wall horizon tally vented gas equipment provides a venting system design or venting system components with the equipment the instruc tions provided by the manufacturer for installation of the equip ment and the venting system shall include 1 Detailed instructions for the installation of the venting system design or the venting system components and 2 Acomplete parts list for the venting system design or venting system d MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED When the manufacturer of a Product Approved side wall hori zontally vented gas fueled equipment does not provide the parts for venting the flue gases but identifies special venting systems the following requirements shall be satisfi
49. es 2 3 4 amp 5 It must be sized per Table 3 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 600 5 127 1000 6 152 1600 6 152 2000 9 229 2600 8 203 3000 8 203 SERIES 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 Direct Intake Air Option Vertical The maximum equivalent length for the vertical intake air pipe is 80 ft 19 7 m for KN 6 10 20 120 ft 36 6 m for KN 16 26 30 Each 90 mitered elbow and the intake air cap are equal to 10 ft 3 3 m of straight pipe If 90 long sweep elbows are installed use the manufacturers recommended equivalent length A listed nonrestrictive intake air cap must be used The intake air cap must terminate as shown in Figure 4 The penetration point in the roof must be properly flashed and sealed Direct Intake Air Option Horizontal The maximum equivalent length for the horizontal intake air pipe is 80 ft 19 7 m for KN 6 10 20 120 ft 36 6 m for KN 16 26 30 Each 90 mitered elbow and
50. f 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 Failure to maintain minimum clearances between vent connectors and any combustible material can result in a fire causing extensive property damage severe personal injury or death Exit cones are favorable when used to increase the velocity of the flue gas exiting the stack and may also help in cold climates to reduce ice build up Exit cone terminations must be supplied by others installed per manufacturer s instructions and meet local and federal code IA generic exit cone Figure 8 Vertical Venting with a Metal Chimney System Note i 1 All building structural modifications _ I by others 2 Firestopping per local building codes OFFSET ONLY IF NECESSARY FIRESTOP FRAMING MEMBERS JOIST BETWEEN JOISTS zx 2FT 6m ABOVE THE HIGHEST POINT WITHIN 10FT 3 1m STORM COLLAR ROOF FLASHING CLEARANCES PER VENT MANUFACTURER S INSTRUCTIONS M INSULATION CLEARANCES PER VENT MANUFACTURER S INSTRUCTIONS BOILER 2 HIOM 7 11 SERIES EXISTING COMMON VENT SYSTEMS If an ex
51. f the total input rating of all ofthe equipment in the enclosure Cast Iron Condensing Boilers Installation Manual 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 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 1 4 in 6 4 mm Metal Wooden Input Wire Screen Louvers Louvers MBH in cm cm 600 150 967 200 1292 3869 1000 250 1612 334 2154 6448 1600 400 2580 533 3439 10 322 2000 500 3224 668 4308 12 896 2600 650 4194 894 5595 16 772 3000 750 4836 1002 6462 19 344 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 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 Figur
52. heating 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 Hydronic Heating Boilers Fill System Open the make up water valve and slowly fill the boiler and all of the radiation with water Ensure that all bleed and drain valves are closed Adjust the make up water pressure regulator so a minimum 5 psig 82 7 kPa system pressure is maintained at the highest point in the system piping A minimum system pressure of 12 psig 84 kPa must be maintained at boiler operating conditions A minimum system pressure of 25 psig 772 kPa fill pressure is required at boiler operating conditions on glycol mixtures within a closed loop 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 radiati
53. in Canada The maximum equivalent length for the total flue outlet vent system for Category IV conditions is 80 ft 19 7 m for KN 6 10 20 120 ft 36 6 m for KN 16 26 30 Use Table 4 for equivalent lengths per fitting Table 4 Category IV Equivalent Length per Fitting chart is meant as a guideline for preliminary sizing If vent length approaches 75 of maximum length listed an engineered vent system calculation must be performed Consult factory SERIES Table 4 Category IV Equivalent Length per Fitting KN6 KN10 KN16 Model Outlet Diameter K 5E 6 6 Standard Tee 1 25 20ft 25ft 25ft Boot Tee 0 65 10ft 15ft 15ft Cap Low Res UL 0 50 10ft 10ft 10ft 45 w Bird Screen 0 40 10ft 10ft 10ft Elbow 90 0 38 10ft 10ft 10ft Elbow 45 0 15 5 ft 5 ft 5 ft KN20 KN26 KN30 Model Outlet Diameter K 8 8 8 Standard Tee 1 25 30ft 35ft 35ft Boot Tee 065 15ft 15ft 15ft Cap Low Res UL 0 50 15ft 15ft 15ft 45 w Bird Screen 0 40 10ft 10ft 10ft Elbow 90 0 38 10ft 10ft 10ft Elbow 45 0 15 5 ft 5 ft 5 ft Equivalent lengths based on K factors and 5X pipe diameters straight length between fittings 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 AI
54. ints in metal pipes must be joined and sealed in accordance with the vent system manufacturer s instructions Combination Direct Vent Systems see Figure 5 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 5 Also follow the general instructions in the COMBUSTION AIR amp VENTILATION and GENERAL VENTING GUIDELINES sections SERIES Cast Iron Condensing Boilers Installation Manual Figure 1 KN Series Multiple Boiler Common Venting DOUBLE ACTING BAROMETRIC DAMPER THERMAL SPILL SWITCH BE T WYE FLUE VENT ALL CONNECTIONS HIOM 51 REV C BOILER 4 IF REQUIRED VERTICAL CHIMNEY VENTING Vertical venting multiple boiler installations DO NOT common vent more than the following numbers of KN boilers KN 6 10 16 5 boilers maximum KN 20 26 30 4 boilers maximum Consult factory for applications requiring more boilers and or use an engineered venting System solution It is recommended that the boiler nearest the vertical chimney be fired first when the horizontal distance exceeds 50 of the vertical distance BOILER 2 IF REQUIRED BOILER 3 IF REQUIRED KN VERTICAL CHIMNEY VENTING MULTIPLE BOILER INSTRUCTIONS When sized for a CAT II configuration a negative pressure of 0 02 to 0 10 in WC is requi
55. ion 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 cAUTION f 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 SERIES 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 Never operate the KN in an environment subjected to a negative pressure unless it is Direct Vented 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 permane
56. isting 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 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 Insofar as is practical close all building doors and windows and all doors betwee
57. jumper to place the boiler at minimum rate 10 Make any final adjustments on low fire 11 Check all combustion results using a calibrated flue gas analyzer 12 Release the LOW FIRE switch to place boiler in standby In addition to completing the KN Series start up report complete the control set up information in the rear of the HeatNet manual ivo EH gt LLI N COMBUSTION ANALYSIS GAS INLET PRESSURE WC CO PPM NET STACK TEMPERATURE AIR BOX DIFFERENTIAL DELTA P WC SAFETY TEST CHECKLIST FLOW SWITCHES By Others LOW WATER CUT OFF Q AIR SWITCH Q HIGH LIMITS COMMISSIONING THE BOILER Q UNIT CYCLED MINIMUM OF 15 TIMES CUSTOMER INSTRUCTED Q ALL COVERS REPLACED 1 CUSTOMER GIVEN MANUAL 1 TARGET TEMPERATURE SET PER CUSTOMER COMMISSIONED BY SIGNATURE DATE ADDITIONAL NOTES AND COMMENTS MINIMUM FIRING RATE INCHES WC Cast Iron Condensing Boilers Installation Manual 10096 FIRING RATE INCHES WC 96 96 INCHES WC FLAME SAFEGUARD THE DELTA T BETWEEN THE HEATER IN LET AND OUTLET IS CRITICAL TO PROP ER FLOW BEFORE YOU LEAVE THE JOB SITE YOU MUST RECORD THE DELTA T THIS READING SHOULD NOT EXCEED 100 F 55 C NOR BE LOWER THAN 20 F 11 1 C 35 Ja 2 2 RET UN Wy 4 NES A N NE SL 57 4 Cast Iron Condensing Boilers
58. l electric power to the appliance 4 Remove the front cover 5 Close manual main shut off valves 1 and 2 and the pilot gas shut off valve Figure 17 6 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 7 Install a fitting at the bleed point and connect a manometer having a minimum range of 20 in 508 mm WC to it Figure 17 8 Remove the 1 8 in pipe plug from the pilot tee and connect a manometer having a minimum range of 154 mm WC to it 9 Wait five 5 minutes to clear out any gas 10 Open the manual main shut off valves 1 and 2 and the pilot gas shut off valve Figure 17 11 Place the Remote Local switch to Remote 12 Turn the power switch on the front of the boiler to on It will light up when the power is on If all interlocks are properly closed the display will say Standby Figure 18 13 Slide the HeatNet controls low fire switch on the HeatNet control board to the low fire position 14 The boiler will begin the start sequence 15 When the main display reads PILOT RUNNING and the flame current is 5VDC switch the Honey well 7800 to the test position Figure 18 This will hold the Honeywell 7800 in its ignition state 16 Adjust the pilot pressure per the CHECKING ADJUSTMENT amp OPERATION on page 27 17 Remove the demand from the 7800 control by disabling th
59. n Figure 19 Electrode tips should face slightly downward Figure 19 Spark Gap 1 8 lt i ES 55 HIOM 16 REV Table 10 Electrode Insertion Depth Model DIM A KN 30 11 2 KN 26 11 2 KN 20 11 2 KN 16 17 8 KN 10 17 8 KN 6 17 8 Pilot Adjustment Verify the pilot pressure has been set within a range of 2 5 in 3 5 in WC To check the pilot pressure close the manual main shut off valve and the pilot gas shut off valve Figure 15 Remove the 1 8 in pipe plug from the pilot tee and connect a manometer having a minimum range of 6 in 754 mm WC to it 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 Cast Iron Condensing Boilers Installation Manual 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
60. n 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 Cast Iron Condensing Boilers Installation Manual Dans la mesure du possible fermer toutes les portes et les fen tres du b timent et toutes les portes entre 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 assurer 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 fa on que l appareil fonctionne de fa on continue After it has been determined that each appliance remaining connected to the common venting system pr
61. ne 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 Cast Iron Condensing Boilers Installation Manual SEQUENCE OF OPERATION NO DEMAND Standby 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
62. nnement 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 also conform with CSA C22 1 Canadian Electrical Code Part if installed in Canada Install a separate 120 volt 15 amp circuit for each KN 6 or KN 10 boiler Install a separate 230 volt 10 with neutral 20 amp circuit for each KN 16 KN 20 boiler 230 volt 30 20 amp circuit required on KN 26 KN 30 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 1114 awg Refer to point of connection diagram in back of this manual and the wiring diagram supplied with the boiler for proper wiring connections SERIES BOILER OPERATION 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 over
63. nt 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 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 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 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 Where directly communicating with the outdoors or communicating with the outdoors through vertical ducts each opening shall have a minimum free area of 1in 4000 Btu hr 550 mm kW o
64. on or other deposits that would impair the boiler s performance Visually inspect the burner through the site glass CAUTION mproper burner servicing can result in premature burner failure voiding the warranty Burner Removal amp Inspection Wear a tightly fitted dust mask when servicing the burner and gently handle the burner and its gasket to prevent inhalation of airborne fibers Do not attempt to remove the burner without having a burner gasket kit on hand 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 replace when required Condensate Pan Remove the 6 bolt base pan door from the front of the boiler Using a hose flush out any residual material in the base pan through the condensate drain opening Re install the base door Flush the drain trap and refill with 5096 water glycol mix to prevent evaporation in the trap Cast Iron Condensing Boilers Installation Manual Controls Use the BOILER OPERATION and CHECKING AND ADJUSTMENT sections 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 instructi
65. on 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 Cast Iron Condensing Boilers Installation Manual The system should be checked and bled after three days of operation OPERATING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE OPERATING ONLY QUALIFIED LICENSED SERVICE TECHNI CIANS SHALL START TROUBLESHOOT AND SERVICE THIS APPLIANCE WITH APPROVED COMBUSTION ANALYZER POUR VOTRE S CURIT LISEZ AVANT DE METTRE EN MARCHE A This appliance is equipped with an ignition 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 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 f you cannot
66. ons 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 If 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 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 6 Visually check the pilot and main burner flames to ensure proper operation see Figures 20 amp 21 Visual flame appearance with proper combustion will have a red and blue striped appearance at low fire and flecked areas of red with a majority of blue across the metal mesh burner at high fire Areas of deep red indicate an infrared condition requiring a combustion adjustment to reduce CO levels Figure 21 Main Burner Flame BLUE FLAME HI
67. ons will be warranted for twenty one 21 years against thermal shock when the boiler is installed as a closed loop hot water boiler This warranty will cover damage due to thermal shock such as leaks to the cast iron sections from cracks from thermal shock This warranty does not cover damage due to corrosion scaling sooting or to improper installation or operation the inlet and outlet water temperature differential across the boiler cannot exceed 100 degrees F Water quality is important As per ASME recommendations dissolved solids must be less than 200 ppm Also PH levels must be in the 6 5 11 range Failure to follow these guidelines will void the warranty This Limited Warranty does not Apply a If the product has been subjected to misuse or neglect has been accidentally or intentionally damaged has not been installed maintained or operated in accordance with the furnished written instructions or has been altered or modified in anyway by any unauthorized person b To any expenses including labor or material incurred during the removal or reinstallation of the product or parts thereof c To products which were not installed and or serviced by a qualified contractor and or serviceman d To burners jackets controls and other auxiliary equipment furnished by the manufacturer but manufactured by others Any warranties for such items shall be limited to those warranties offered by the original equipment manufacturer e To any w
68. operly 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 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 fa or 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 SERIES GENERAL PIPING REQUIREMENTS CAUTIO
69. orkmanship by any installer of the product This limited Warranty is Conditional Upon a Shipment to the manufacturer of that part of the product thought to be defective Goods may only be returned with prior written approval of the manufacturer All returns must be freight prepaid b Determination in the reasonable opinion of the manufacturer that there exists a defect in material or workmanship Repair or replacement of any part under this Limited warranty shall not extend the duration of the warranty with respect to such repaired or replaced part beyond the stated warranty period THIS LIMITED WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES EITHER EXPRESSED OR IMPLIED AND ALL SUCH OTHER WARRANTIES INCLUDING WITHOUT LIMITATION IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY DISCLAIMED AND EXCLUDED FROM THIS LIMITED WARRANTY IN NO EVENT SHALL THE MANUFACTURER BE LIABLE IN ANY WAY FOR ANY CONSEQUENTIAL SPECIAL OR INCIDENTAL DAMAGES OF ANY NATURE WHATSOEVER OR FOR ANY AMOUNTS IN EXCESS OF THE SELLING PRICE OF THE PRODUCT OR ANY PARTS THEREOF FOUND TO BE DEFECTIVE THIS LIMITED WARRANTY GIVES THE OWNER AT THE ORIGINAL INSTALLATION SITE SPECIFIC LEGAL RIGHTS YOU MAY ALSO HAVE OTHER RIGHTS WHICH MAY VARY BY EACH JURISDICTION HydroTherm VS MESTEK COMPANY Z IN UNITED STATES 260 NORTH ELM ST WESTFIELD 01085 413 564 5515 FAX 413 568 9613 7555 TRANMERE DRI
70. primary loop tee Figure 13 Typical Multiple Boiler Primary Secondary Piping AIR SEPARATOR ALTERNATE LOCATION SYSTEM f RETURN t bh MINIMUM 3X PIPE DIAMETERS MAXIMUM 10X PIPE DIAMETERS BETWEEN CENTERS AIR SEPARATOR 04 TYPICAL LOCATION y SYSTEM COLD WATER SUPPLY MAKE UP HIOM 10 REV 6 NOTE Not all system valves may be shown Consult local codes for additional system components which may be necessary For HeatNet operation a sensor is required and installed at a minimum of 12 from primary loop tee 4g Motorized Valve Pump lt Gate Valve N Check Valve m Backflow Prevention Device Pressure Relief Valve E Thermometer Expansion Tank T Aquastat Jk Pressure Reducing Valve Tangential type air separator Heat Net Sensor SERIES DOMESTIC WATER SUPPLY PIPING CAUTION Proper controls must be used to prevent water supplied for domestic use from exceeding 130 F 54 or a scald injury will occur When higher water temperatures are required for appliances such as a dish washer 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 Gen
71. 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 part 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 21 22 SERIES 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 and disable any outside BMS call for heat 3 Turn off al
72. red in each boiler s riser when all boilers are operating at full input A barometer damper must be installed as illustrated Exception if the vent system is designed using accepted engineering practices and the design calculations prove there is no need for barometric dampers the barometric dampers may be omitted When required by applicable codes install a thermal spill switch on each barometric damper When engineered for a CAT IV configuration KN 16 26 30 only do not exceed a positive pressure of 0 50 inches WC in each boiler riser when all boilers are operating at high fire 1 Connect each boiler riser to the common vent with a Y or boot T 2 Install an approved vent cap at each vent termination 3 Dimensions B breeching length C chimney height D breeching diameter F riser diameter No smaller than the dimension given in Table 4 page 6 4 Size the chimney and breeching per local codes and vent pipe manufacturer s recommendation using generally accepted engineering practices Consult factory for vertical heights beyond 100 ft Cast Iron Condensing Boilers Installation Manual SERIES Figure 2 Horizontal Air Intake and Venting for a Single Direct Vent System PITCH PIPE DOWN TOWARDS BOILER 1 4 IN PER FOOT 20 mm m PITCH PIPE DOWN TOWARDS TERMINAL CAP 1 4 IN PER FOOT 20 mm m 16 FT 4 9 m MINIMUM gt TO ADJACENT BUILDING
73. s foam significantly decreases heat transfer and could potentially result in damage to the sections The formation of this foam can be controlled rather simply by introducing an anti foaming agent to the water glycol mix There are many suppliers of chemical treatments that are acceptable the following company offers a mix with a heat transfer characteristics nearly identical to water a mixture of one gallon of anti foaming agent per 5 000 gallons of system volume Dow Corning Anti foaming Agent part 1410 or equivalent 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 55 6 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 Reverse Return Piping RECOMMENDED Systems using multiple boilers can also be installed using a reverse return sys
74. s shown to be defective Five Year Warranty The manufacturer further warrants to the original owner at the original installation site that the products Heat Exchanger Cast Iron Block will be free from defects in material and workmanship for five 5 years from the date of shipment from the factory If upon examination by the manufacturer the product is shown to have a defect in material or workmanship during the warranty period the manufacturer will repair or replace at its option the Heat Exchanger of the product which is shown to be defective Ten Year Warranty The manufacturer further warrants to the original owner at the original installation site the products Heat Exchanger Cast lron Block will be free from defects in material or workmanship for Ten 10 years from the date of shipment from the factory If upon examination by the manufacturer the Heat Exchanger is shown to have a defect in material or workmanship during the warranty period the manufacturer will replace the Heat Exchanger upon payment of a percentage of the manufacturer s trade price in effect at the time of the claim prorated to the year in which the claim is made as show below Replacement Cost Schedule Year of Claim 6 7 8 9 10 96 Of trade price at the time of claim charged to the consumer 55 60 65 70 75 Twenty One Year Thermal Shock Warranty The manufacturer further warrants to the original owner at the original installation site that the products Cast Iron Secti
75. sponds to full input for applications requiring operation above and or below these parameters please consult manufacturer Increase flow rates approximately 30 for glycol mixtures Figure 9 Relief Valve Piping DISCHARGE PIPE SIZE TO EQUAL VALVE OUTLET DO NOT RESTRICT FLOW SUPPLY OUTLET RETURN INLET FLUE OUTLET PRESSURE RELIEF VALVE HI LIMIT LOW WATER CUT OFF TEMP PRESSURE GAUGE OPTIONAL AIR VENT LOCATION gos ooo 4 CONDENSATE DRAIN ASSY HIOM 8 REV B DISCHARGE SO AS TO AVOID EXPOSURE OF PERSONS TO HOT LIQUID OR VAPOR AND ALLOW COMPLETE DRAINAGE OF RELIEF VALVE AND PIPING 13 SERIES 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 system must be considered when supporting the system A minimum system pressure of 12 psig 84 kPa must be maintained
76. sword value of 523 then press Mode The parameters of the drive will be accessible at this point Use the Arrow Keys on the AC Tech Drive to scroll to P45 Press Mode to view the entry use the Arrow Keys to adjust the value to achieve the required combustion CO2 C2 Table 11 and pressure delta p Table 12 at low fire based on the desired turn down The default values are listed below on Table 12 Adjust low fire O2 CO2 by opening the low fire adjustment door located on the forward facing side of the main gas valve Figure 17 Inserting an allen wrench and rotating the allen screw clock wise will increase the CO2 and lower the O2 rotating counter clock wise will decrease the CO2 and increase the O2 When complete press Mode again to save the value 25 Setting the Max VFD and High Fire Combustion values KN16 KN26 amp KN30 a Place the S2 Calibration switch located on the 3 0 HeatNet board to the Cal position The display will indicate Calibrate Press the arrow key until Max VFD is shown on the display Press the select key for approximately one second The percentage value will drop to 8096 and start flashing indicating that it can be adjusted Boiler input will increase to a higher input Adjust max input to achieve the required combustion CO2 O2 Table 11 and pressure delta p Table 12 o d e Cast Iron Condensing Boilers Installation Manual A high fir
77. table 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 Service clearances are not mandatory but are recommended to ensure ease of service should it be required Table 1 Clearances Clearance to Combustibles Service Clearance in mm in mm Top 6 153 24 610 Back 6 153 24 610 Left Side 6 153 6 152 Right Side 6 153 6 152 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 water or excessive moisture during operation or servicing 3 Ensure that the floor is structurally sound and will support the weight of the boiler Cast Iron Condensing Boilers Installation Manual 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
78. tem Figure 11 SERIES Primary Secondary Piping Although acceptable the system is not as cost effective as reverse return piping Figure 12 shows a typical primary secondary piping system A dedicated pump is used to maintain a constant water flow through the boiler Systems using multiple boilers can be installed using a primary secondary manifold system Figure 13 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 Cast Iron Condensing Boilers Installation Manual 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 It is essential that following boiler shut off the boiler pump continue to operate for approximately 5 minutes to dissipate the heat away from the heat exchanger Figure 10 Typical Single Boiler Piping RECOMMENDED Circulator pump must be sized for minimum water flow rate of boiler including system pressure drop SYSTEM RETURN SYSTEM SUPPLY HIOM 64 NIN Backflow Prevention Pressure Device Pump Gate Valve Relief Valve nermometer COL
79. the intake air terminal are equal to 10 ft 3 3 m of straight pipe If 90 long sweep elbows are installed use the manufacturers recommended equivalent length Horizontal runs that exceed 5 ft 1 5 m must be supported at 3 ft 0 98 m intervals with overhead hangers The intake air terminal must terminate as shown in Figures 2 3 or 5 GENERAL VENTING GUIDELINES 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 Improper installation of common positive pressure vent systems can result in excessive levels of carbon monoxide which can cause severe personal injury or death Cast Iron Condensing Boilers Installation Manual A single acting barometric damper or blast gate as required must be installed if a vertical vent system produces a negative draft in excess of 0 2 in 5 08 mm WC at the flue outlet See Figure 1 for location of barometric damper multiple when applied boiler as common venting system VENT SYSTEM OPTIONS The KN may
80. ty to meet the demand Figure 17 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 ft 7 m 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 with the type of gas NG LP being used Table 8 Gas Pipe Capacity Maximum pipe capacity in ft hr based 0 60 specific gravity gas at a 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 Maximum gas volume of pipe ft hr 520 350 285 245 215 195 170 150 120 TA 1050 730 590 500 440 400 350 305 250 12 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 Multiply the propane flow capacity by 2500 Btu ft3 to determine the propane Btu hr capacity for a given pipe size and length 20 SERIES Table 9 Equivalent Pipe Length Chart
81. ualifi ou par le fournisseur de gaz Failure to properly vent this unit can cause excessive amounts of carbon monoxide resulting in severe personal injury or death Do not use automotive anti freeze in the boiler waterways If the use of anti freeze is necessary an anti freeze specifically formulated for hydronic heating systems must be used or damage to the boiler may occur voiding the warranty 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 INSTALLER THESE INSTRUCTIONS TO BE AFFIXED ADJACENT TO THE BOILER WATER HEATER CONSUMER RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE PURPOSES CAUTION Cast Iron Condensing Boilers Installation Manual CONTENTS Before Your page 2 Ratings amp Capacities page 3 3 Combustion Air amp Ventilation page 3 Venting Guidelines page 5 Common Vent Systems page 12 General Piping Requirements page 13 Heating System Piping page 14 Domestic Water Supply Piping page 17 Condensate Piping page 19 Gas Supply Piping page 19 Electrical Wiring
82. um input to full load of the gas supply line and all the appliances running 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 CAUTION Safe lighting and other performance criteria were 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 Cast Iron Condensing Boilers Installation Manual 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 17 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 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 un fonctio
83. will start and will run at minimum input rate 24 Setting the Min VFD and Low Fire Combustion values The boiler will cycle and achieve low fire status Allow low fire to settle out for a few minutes and observe the combustion reading KN16 KN26 amp KN30 a Place the S2 Calibration switch located on the 3 0 HeatNet board to the Cal position The display will indicate Calibrate b Press the up arrow key until Min VFD is shown on the display Press the select key for approximately one second The percentage value will start flashing indicating that it can be adjusted Adjust min percentage to achieve the required combustion CO2 O2 Table 11 and pressure delta p Table 12 at low fire based on the desired turn down KN6 SERIES Adjust low fire O2 CO2 by opening the low fire adjustment door located on the forward facing side of the main gas valve Figure 17 Inserting an allen wrench and rotating the allen screw clock wise will increase the CO2 and lower the O2 rotating counter clock wise will decrease the CO2 and increase the O2 When complete press the select key once to clamp the desired setting KN10 amp KN20 Follow the instructions in the HeatNet manual to set the required turndown percentage Utilize the AC Tech Drive to trim the low fire input Press the Mode button on the AC Tech Drive The drive will now require a password Use the Arrow Keys on the AC Tech Drive to enter the pas

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