HydroTherm KN-16 Field Assembly Instructions
Kn series gas boiler
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Also See for KN-16:
- User information (108 pages) ,
- Installation and operation instructions manual (48 pages)
Table of Contents
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Th is manual is intended only for use by a qualifi ed 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.
the burner, resulting in possible severe personal injury, death or substantial property damage. Th e boiler can only be operated with a dust-
free air supply. Follow the instruction manual procedures to duct air to the boiler air intake. If the boiler has been contaminated by operation
with contaminated air, follow the instruction manual guidelines to clean, repair or replace the boiler if necessary.
Affi x these instructions near to the boiler/water heater. Instruct the building owner to retain the instructions for future use by a qualifi ed
service technician, and to follow all guidelines in the User' s Information Manual.
Gas-Fired Cast Iron Boilers
Models K N-16, -26, and - 30
Field Assembly
Instructions
Also read and follow:
KN Series Gas Boiler
Installation and Operating
Instructions
and
KN HeatNet Control Manual
Construction dust and particulate, particularly drywall dust, will cause contamination of
KN-FAI2-0313
42-9552
10/12 Copyright 2010 Hydrotherm
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Table of Contents
Related Manuals for HydroTherm KN-16
Summary of Contents for HydroTherm KN-16
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Page 1: Field Assembly
Affi x these instructions near to the boiler/water heater. Instruct the building owner to retain the instructions for future use by a qualifi ed service technician, and to follow all guidelines in the User’ s Information Manual. 10/12 Copyright 2010 Hydrotherm... -
Page 2: Read Before Proceeding
INFORMATION READ BEFORE PROCEEDING This manual is intended only for the fi eld assembly of a KN-16, -26 or -30 boiler. Follow the assembly Customer Service And Technical Support instructions in sequence. Also follow all requirements Direct all questions to your HydroTherm distributor or of the KN Boiler manual and the KN HeatNet manual. - Page 3 Use the Checklist to locate specifi c items throughout the assembly process. Content Line voltage fi eld wiring of any controls or other your Hydrotherm supplier if you discover any devices must use copper conductors with a components damaged or missing.
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Page 4: Front End
Gas-Fired Direct Vent Cast Iron Boilers – Field Assembly Instructions Step 1 Place runner beams on base (see BLOCK ASSEMBLY SEQUENCE NO- TICE on page 2 — assembly can be from back to front if necessary) FRONT END FRONT END (legs extend longer at (legs extend longer at Make sure the boiler base is in the correct position before front than at rear) - Page 5 Gas-Fired Direct Vent Cast Iron Boilers – Field Assembly Instructions Step 4 Place the FRONT section Use leather gloves when 1. Identify the FRONT section — its lift ing or moving boiler lower nipple port is on the LEFT side sections.
- Page 6 Gas-Fired Direct Vent Cast Iron Boilers – Field Assembly Instructions Step 7 Place ceramic fi ber baffl e in fl ueway Use of an approved dust 1. The cut-off corner of the baffl e must respirator is strongly go to the lower left corner. Align the recommended when baffl e in this position to determine handling the insulating...
- Page 7 Gas-Fired Direct Vent Cast Iron Boilers – Field Assembly Instructions Step 10 Apply RTV to machined surfaces Rubber gloves are 4. Keep the bead of silicone close to the 5. This will protect the machined nipple recommended for this INSIDE edge of the nipple ports. port surfaces from condensation that procedure.
- Page 8 Gas-Fired Direct Vent Cast Iron Boilers – Field Assembly Instructions Step 14 File lower edges of next section Work gloves are 1. Use a fl at fi le to ease off the front recommended for this lower edge on both sides of the next procedure.
- Page 9 Gas-Fired Direct Vent Cast Iron Boilers – Field Assembly Instructions Step 16 Draw sections together using draw rods and dead blow hammer 1. Use wrenches to pull the sections 6. Look inside the nipple ports from the together. end and inspect the push nipples. They should be parallel with the section face and about 1/8 inch from the inside surface of the section.
- Page 10 Gas-Fired Direct Vent Cast Iron Boilers – Field Assembly Instructions Step 18 Remove the runner beams and bolt block to base The block assembly is 4. Pull the runner beam out. 7. Check alignment of the section leg slots Use care extremely heavy.
- Page 11 Gas-Fired Direct Vent Cast Iron Boilers – Field Assembly Instructions Step 20 Remove excess silicone sealant along top of block and in chamber area 1. Remove excess silicone sealant along the top the block until it is fl ush with the machined surface.
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Page 12: Outlet Manifold
10. If pressure drops, perform a thorough block leaks should occur, inspection to locate the leak. repair if possible. Contact your Hydrotherm representative for 11. Repair any leaks found before 3. Plug any unused openings in the boiler. instructions if necessary. - Page 13 Gas-Fired Direct Vent Cast Iron Boilers – Field Assembly Instructions Step 26 Install burner inspection ports (front and rear) 1. Each burner inspection port consists of a plate, gasket, inspection glass, and another gasket. 2. Place against the mounting boss on the top front section.
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Page 14: Step 29 Install The Burner
Gas-Fired Direct Vent Cast Iron Boilers – Field Assembly Instructions Step 29 Install the burner Make sure the silicone sealant is continuous. Failing to provide a complete seal could result in the leakage of combustion gases. Use of an approved dust respirator is strongly recommended when handling the insulating components of... - Page 15 Gas-Fired Direct Vent Cast Iron Boilers – Field Assembly Instructions Step 32 Install the rear jacket and fl ue collar Make sure the silicone sealant is continuous. Failing to provide a complete seal could result in the leakage of combustion gases. 1.
- Page 16 Gas-Fired Direct Vent Cast Iron Boilers – Field Assembly Instructions Step 35 Install condensate drain trap assembly The condensate drain pan trap be sealed to the drain pan with the gasket provided to prevent fl ue gas leakage. 1. Condensate drain trap components. 3.
- Page 17 Gas-Fired Direct Vent Cast Iron Boilers – Field Assembly Instructions Step 37 Install the blower housing 1. Place the blower housing bracket over the top two studs. 2. Rest the blower housing on the bracket and secure the four bolts between the blower housing fl ange and the manifold.
- Page 18 Gas-Fired Direct Vent Cast Iron Boilers – Field Assembly Instructions Step 39 Access the blower housing interior, adjust magnetic damper closure and connect wiring 1. Remove the covers on the blower 3. Connect wires from blower housing housing. components to control panel. 2.
- Page 19 Gas-Fired Direct Vent Cast Iron Boilers – Field Assembly Instructions Step 42 Install the jacket right side insulation and panel; install control enclosure side panels Use of an approved dust respirator is strongly recommended when handling the insulating components of the boiler. 1.
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Page 20: Step 46 Complete Wiring
Gas-Fired Direct Vent Cast Iron Boilers – Field Assembly Instructions Step 45 Replace access panels on blower housing 1. Re-install all access panels on the blower housing. Step 46 Complete wiring 1. Obtain the HeatNet display panel 3. Mount the display panel and the control 5. - Page 21 Gas-Fired Direct Vent Cast Iron Boilers – Field Assembly Instructions Step 47 Completed boiler images 1. Front left view. 3. Rear, showing piping and components. 5. Top front components. 2. Front right view. 4. Top rear components. 6. Manifold top. Step 48 Follow Boiler Installation and Operating Instructions manual and HeatNet Control manual 1.
- Page 22 Gas-Fired Direct Vent Cast Iron Boilers – Field Assembly Instructions Figure 1 Plastic tube routing...
- Page 23 Gas-Fired Direct Vent Cast Iron Boilers – Field Assembly Instructions Figure 2 Boiler materials Crate 1 Filter box assembly kit Skid 1 Pilot assembly kit Sections (front, back and intermediate) View ports assembly kit Long bolts for temporary attachment of front and rear Rear jacket panel assembly kit sections to base Front jacket panel assembly kit...
- Page 24 IN UNITED STATES: 260 NORTH ELM ST. • WESTFIELD, MA 01085 • (413) 564-5515 • FAX (413) 568-9613 IN CANADA: 7555 TRANMERE DRIVE • MISSISSAUGA, ONT. L5S 1L4 • (905) 672-2991 • FAX (905) 672-2883 www.hydrothermkn.com...