ATH KN Series Installation And Operation Instructions Manual
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ATH KN Series Installation And Operation Instructions Manual

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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.
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. 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.
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. Dimensions are in INCHES (IN), FEET (FT),
MILLIMETERS [mm] or METERS [m].
Boiler Manual
Installation and Operation
Instructions
Cast Iron Condensing Boilers
KN-Series Plus
KN6+, KN10+, KN16+, KN20+,
KN26+, KN30+ and KN40+
Also read and follow:
KN Control Manual
Construction dust and particulate, particularly drywall dust, will cause contamination of
KNP-IOM2-1221
12/2021 Copyright 2014 Advanced Thermal Hydronics
42-9555

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  • Page 1 KNP-IOM2-1221 42-9555 Boiler Manual Installation and Operation Instructions Cast Iron Condensing Boilers KN-Series Plus KN6+, KN10+, KN16+, KN20+, KN26+, KN30+ and KN40+ Also read and follow: KN Control Manual 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.

  • Page 2: Table Of Contents

    Cast Iron Condensing Boilers – Installation Manual CONTENTS If the information in this manual is not followed exactly, a fire or explosion may result causing Before Your Start ..........page 2 property, personal injury or loss of life. Ratings & Capacities .......... page 3 Location ..............

  • Page 3: Ratings & Capacities

    Cast Iron Condensing Boilers – Installation Manual The KN + may be installed directly on The owner should maintain a record of all service work performed with the date and a description of the work combustible flooring, but never on carpeting. done.
  • Page 4 Cast Iron Condensing Boilers – Installation Manual Buildings will require the installation of a fresh air duct Where communicating with the outdoors through hori- or other means of providing make-up air if the intake zontal ducts, each opening shall have a minimum free /2000 Btu/hr, 1100 mm /kW of the total air option isn't used.

  • Page 5: Venting Guidelines

    Cast Iron Condensing Boilers – Installation Manual All joints in metal intake air systems must be A barometric damper or blast gate as required, secured using corrosion resistant fasteners must be installed if a Category II vertical vent and sealed using a suitable Silicone caulk. If system produces a negative draft in excess of 0.15 in, 3.8 mm WC at the flue outlet.
  • Page 6 Cast Iron Condensing Boilers – Installation Manual DIRECT VENT Use (Table 4) for the maximum Category (IV) equivalent vent length and the equivalent POSITIVE PRESSURE, CATEGORY IV length per fitting. Table 4 - “Category IV In this configuration the boiler blower is used to push Equivalent Length per Fitting”...
  • Page 7 Cast Iron Condensing Boilers – Installation Manual Avoid terminal locations likely to be affected by winds, The top of a vertical vent system must extend at least ft, 1.8 m above the roof surface that it passes snowdrifts, people and pets. Protect building materials through, 4 ft, 1.3 m above the intake air cap, see Figure and vegetation from degradation caused by the flue gases.
  • Page 8 Hood *with bird screen The ATH KN-Series Plus is supplied with a factory installed DuraVent FastNSeal flue outlet adapter. A manufacturers supplied stainless steel transition piece must be used when installed with different vent systems. Do not mix vent systems of different manufacturers. Use only listed vent manufacturers (Table X), terminations (Table Y), and transition adapters (Table Z).
  • Page 9 Cast Iron Condensing Boilers – Installation Manual Table Z - Approved Manufacturers Stainless Steel Boiler Transition Adapters (CAT II/IV) M&G DuraVent DuraVent Metal-Fab (DuraSeal) Model Size Boiler Transition Transition Transition Flue Flue Flue Flue Adapter* Adapter Adapter Adapter DS5FFNSAU HM-5AC 810013226 5FCSLXL DSD5FFNSAUK...
  • Page 10 Cast Iron Condensing Boilers – Installation Manual Figure 1 - KN-Series Plus Multiple Boiler Common Venting FLUE VENT "B" DOUBLE ACTING ALL CONNECTIONS "C" BAROMETRIC DAMPER TO BE "T-WYE" "D" THERMAL SPILL SWITCH "F" AIOM-105_B BOILER #4 BOILER #3 BOILER #2 BOILER #1 (IF REQUIRED) (IF REQUIRED)
  • Page 11 Cast Iron Condensing Boilers – Installation Manual Figure 2 - Horizontal Air Intake and Venting for a Single Direct Vent System PITCH PIPE DOWN TOWARDS BOILER PITCH PIPE DOWN 1/4 IN/FT TOWARDS TERMINAL [20 mm/m] CAP 1/4 IN/FT [20 mm/m] 10 FT [3.1 m] EXHAUST MINIMUM...
  • Page 12 Cast Iron Condensing Boilers – Installation Manual Figure 4 - Vertical Air Intake and Venting for Direct Vent System AIOM-003_C Figure 5 - Combination Direct Vent Systems MAXIMUM EXHAUST COMBUSTION AIR MAXIMUM...
  • Page 13 Cast Iron Condensing Boilers – Installation Manual SIDE WALL VENT The air for combustion is taken from the space in which the unit is installed. The applicable instructions under POSITIVE PRESSURE, CATEGORY IV the COMBUSTION AIR & VENTILATION section must In this configuration the boiler blower is used to push the be followed! The vent guidelines under the Horizontal flue products horizontally to the outdoors, see Figure 6.
  • Page 14 Cast Iron Condensing Boilers – Installation Manual VERTICAL VENT (Optional) The vent system should be sloped up toward the chimney at a minimum rate of 1/4 in/ft, 2 cm/m. NEGATIVE PRESSURE - CATEGORY II The KN + is listed as a Category II appliance when Always provide a minimum clearance of 6 in, 152 mm vented vertically into a listed metal AL294C S.S.

  • Page 15: Common Vent Systems

    Cast Iron Condensing Boilers – Installation Manual EXISTING COMMON VENT SYSTEMS Dans la mesure du possible, fermer toutes les portes et les fenêtres du bâtiment et toutes les portes entre If an existing boiler is removed from a common venting l'espace où...
  • Page 16 Cast Iron Condensing Boilers – Installation Manual Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual Figure A - Direct Vent Terminal Clearances Canadian Installations¹ US Installations² Clearance above grade, veranda, porch, 12 in (30 cm) 12 in (30 cm) deck, or balcony 6 in (15 cm) for appliances <...
  • Page 17 Cast Iron Condensing Boilers – Installation Manual Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual Figure A - Direct Vent Terminal Clearances - Concluded Clearance to a mechanical air 3 ft (91 cm) above if within 10 ft (3 m) 6 ft (1.83 m) supply inlet horizontally...
  • Page 18 Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual Cast Iron Condensing Boilers – Installation Manual Figure A - Other Than Direct Vent Terminal Clearances - Concluded Clearance to a mechanical air supply 3 ft (91 cm) above if within 10 ft (3 m) 6 ft (1.83 m) inlet horizontally...

  • Page 19: Outdoor Venting

    Cast Iron Condensing Boilers – Installation Manual OUTDOOR VENTING Figure 8B - Multiple Outdoor Units When installed outdoors the KN + must be fitted with the factory supplied outdoor hood, air intake adapter with filter and exhaust terminal, see Figure 8A. Multiple units must be spaced per Figure 8B.

  • Page 20: General Piping Requirements

    Cast Iron Condensing Boilers – Installation Manual GENERAL PIPING REQUIREMENTS Table 6 - Temperature Rise Table Water Flow Rates (GPM) Model Improper piping of this boiler will void the 100%-Input 10%-Input Size manufacturer’s warranty and can cause Min.* Max.* Min. boiler failure resulting in flooding and 11.5 57.7...

  • Page 21: Heating System Piping

    Cast Iron Condensing Boilers – Installation Manual HEATING SYSTEM PIPING Magnetite, Iron Oxides must be flushed from the system prior to commissioning the boiler(s). The PH level must be within the 6.5-11 range. Where required, the system General Piping Requirements must be protected by the addition of a corrosion inhibitor All heating system piping must be installed by a qualified per the chemical supplier’s instructions.
  • Page 22 Cast Iron Condensing Boilers – Installation Manual Reverse Return Piping (RECOMMENDED) Piping For Use With Cooling Units Consideration of system thermal mass, minimum The boiler, when used in connection with a refrigeration system load & system flow must be based on the system, must be installed so the chilled medium is piped in parallel with the boiler.
  • Page 23 Cast Iron Condensing Boilers – Installation Manual 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 RETURN...

  • Page 24: Domestic Water Supply Piping

    Cast Iron Condensing Boilers – Installation Manual DOMESTIC WATER SUPPLY PIPING The storage tank must be located as close to the boiler as possible to prevent excessive Proper controls must be used to prevent head loss which will reduce flow. water supplied for domestic use from exceeding 130°F, 54°C or a scald injury will Expansion Tank...
  • Page 25 Cast Iron Condensing Boilers – Installation Manual Figure 15 - Typical Multiple Boiler with Indirect Storage Tank Piping NOTES: 1. LOCATE HEAT NET SENSOR WITH WELL IN LOWER 1/3 OF TANK. INSTALL SENSOR WITH HEAT SENSING COMPOUND. 2. THERMAL EXPANSION TANK MAY BE REQUIRED, CHECK LOCAL CODES. 3.

  • Page 26: Condensate Piping

    Cast Iron Condensing Boilers – Installation Manual CONDENSATE PIPING Do not size the gas supply line nominal iron pipe size based only on the boiler gas inlet connection size. The The condensate trap provided with the boiler must be gas supply line (feed) to the boiler gas inlet connection attached to the bottom pan and piped to a suitable floor must be designed per an engineered method and drain (consult local code) or condensate pump.

  • Page 27: Electrical Wiring

    Cast Iron Condensing Boilers – Installation Manual Figure 17 - Gas Supply Piping Corruption of the gas train components with debris and cutting oils can reduce reliable operation which can have a negative effect on the operation & manufacturers warranty of the Dungs gas valve.

  • Page 28: Boiler Operation

    Cast Iron Condensing Boilers – Installation Manual BOILER OPERATION The system should be checked and bled after three days of operation. Before proceeding read and fully understand OPERATING INSTRUCTIONS the instructions contained in this manual. Do not attempt to operate this boiler if it has FOR YOUR SAFETY READ BEFORE OPERATING.
  • Page 29 Cast Iron Condensing Boilers – Installation Manual Operating Instructions - (5:1) Startup 14. The boiler will begin the start sequence. Procedure. (Refer to page (31) for 10:1 Field 15. When the main display reads "PILOT RUNNING" and Startup Instructions.) the flame current is 5VDC, switch the Honey well 7800 1.
  • Page 30 Cast Iron Condensing Boilers – Installation Manual 20. Switch the Honeywell 7800 back to "run". c. Adjust low fire 02-C02 by opening the low fire adjustment door located on the forward 21. Create a minimum input demand as before (enable facing side of the main gas valve, (Figure 17).
  • Page 31 Cast Iron Condensing Boilers – Installation Manual Operating Instructions - (10:1) Startup 14. The boiler will begin the start sequence. Procedure. (Refer to page (29) for 5:1 Field 15. When the main display reads "PILOT RUNNING" and Startup Instructions.) the flame current is 5VDC, switch the Honey well 7800 1.
  • Page 32 Cast Iron Condensing Boilers – Installation Manual 20. Switch the Honeywell 7800 back to "run". b. Write down the Min Air Shutter Setting! This is a factory calculated setting. Press the 'Adjust' 21. Create a minimum input demand as before (enable button under the Min Air Shutter setting.
  • Page 33 Cast Iron Condensing Boilers – Installation Manual 26. Setting the Blower Clamp: 29. When the adjustment is satisfactory press the green check mark to save the setting. The boiler will return a. Measure the differential pressure across the Air to low fire. Shutter, (Figure18a &...
  • Page 34 Cast Iron Condensing Boilers – Installation Manual The HeatNet High Turndown menu screen provides the following informational data: a. The Modulation graph indicates the boiler input KN6 + , 10 + , 16 + , 20 + , 26 + , 30 + , 40 + High Fire CO percentage.

  • Page 35: Sequence Of Operation

    Cast Iron Condensing Boilers – Installation Manual SEQUENCE OF OPERATION Instructions De Mise En Marche 1. ARRÊTEZ! Lisez les instructions de sécurité sur la portion supérieure de cette étiquette. NO DEMAND Standby 2. Réglez le thermostat à la température la plus basse. 1.
  • Page 36 Cast Iron Condensing Boilers – Installation Manual Table 11 - Combustion Settings KN-Series Plus Whirlwind Bekaert Burner w/Gas Orifice Slide Trim** Inlet Low Fire Low Fire Low Fire High High High Temp. Fire Fire Fire 10.3 -40°F 10.5 -30°F 10.6 -20°F 10.7 -10°F 10.8 0°F 10.9...

  • Page 37: Ignition Troubleshooting

    Cast Iron Condensing Boilers – Installation Manual KN- Series Plus "Heat Net Control" Troubleshooting (Firing the KN Boiler) KN + Control Functions Ignition Contrrol Ametek Fan Hand Shake Ignition Sequence (Honeywell S7800) DISPLAY: INPUTS: 1. MODBUS STANDBY CALL FOR 2. AA HEAT? 3.Heat Demand 4.

  • Page 38: Checking & Adjustment

    Cast Iron Condensing Boilers – Installation Manual CHECKING, ADJUSTMENT & Table 13 Recommended Electrode Insertion Depth, ± 1/4" OPERATION Model DIM “A” " Spark Gap " The gap has to be measured and adjusted with the igniter removed from the boiler. Observe the trial for "...

  • Page 39: Diagnostics

    Cast Iron Condensing Boilers – Installation Manual Figure 20 - Pilot Flame 6. Input = 10 / seconds (Btu per cu/ft)(3600). TEST PORT 7. If the computed rate exceeds the desired input follow section “operating instructions” to make the appropriate adjustments. 1 1/2 TO 2"...

  • Page 40: Maintenance

    Cast Iron Condensing Boilers – Installation Manual MAINTENANCE Controls Use the BOILER OPERATION and CHECKING AND ADJUSTMENT sections of this manual for reference. Disconnect electrical power and close the 1. Check the operating controls for proper operation. manual gas shut off valve before performing maintenance or severe personal injury may 2.

  • Page 41: Pressure Switches

    Cast Iron Condensing Boilers – Installation Manual Figure 22 - KN6+, 10+, 16+, 20+, 26+, 30+ and 40+ Pressure Switches IGNITOR BLOCK ASSEMBLY FILTER BOX - TOP VIEW UV SCANNER BLOWER PROVE PRESSURE SWITCH AIR PUMP REAR P1 (+) ORANGE FRONT P2 (-) FRONT(+) REAR(-)

  • Page 42: Wiring

    Cast Iron Condensing Boilers – Installation Manual Figure 23 - KN6+, 10+, 16+, 20+, 26+, 30+ and 40+ Relays, Interlocks and Boiler Status The Highest priority SYSTEM FLOW PROVE --------- Low Water Cutoff------------------- Variable Frequency Drive -------- Gas Pressure (High & Low) ----- Spare for user or Factory ------ Operator------------------------------ Water Flow Switch-----------------...

  • Page 43: Start-Up

    Cast Iron Condensing Boilers – Installation Manual START-UP REPORT DATE: JOB NAME: TECHNICIAN: LOCATION: COMPANY: MODEL: PHONE NUMBER: SERIAL #: PRE-STA T T RTUP CHECK LIST NO VISIBLE DAMAGE TO UNIT INLET AIR FILTER INSTALLED AND CLEAN PIPING PROPERLY CONNECTED PROPER SERVICE CLEARANCES PROVIDED BOILER CIRCULATOR WIRED PUMP RUNNING, HEAT EXCHANGER FULL...
  • Page 44 Cast Iron Condensing Boilers – Installation Manual CO M BUSTI O N ANAL L YSIS MINIMUM FIR I NG RATE 1 00% FIR IN G RATE GAS INLET PRESSURE (WC) INCHES WC I NCHES WC CO ( PPM ) PP M NET S TA C K TEMPERAT U R E SIGNAL PRESSURE (DELTA P - WC) INCHES WC...
  • Page 45 Cast Iron Condensing Boilers – Installation Manual Figure 24 - KN6+, 10+, 16+, 20+, 26+, 30+ and 40+...
  • Page 46 Cast Iron Condensing Boilers – Installation Manual Figure 25 - KN6+, 10+, 16+, 20+, 26+, 30+ and 40+...
  • Page 47 Cast Iron Condensing Boilers – Installation Manual Figure 26 - Gas Train/Drain Pan...
  • Page 48 Cast Iron Condensing Boilers – Installation Manual Figure 27 - Control Panel Figure 28 - Secondary Heat Exchanger Assembly...

  • Page 49: Repair Parts

    Cast Iron Condensing Boilers – Installation Manual SERVICE AND REPLACEMENT PARTS LIST - KN6+, KN10+, KN16+, KN20+, KN26+, KN30+ and KN40+ Model Size with Item Quantities Below Name of Part Part No. KN6+ KN10+ KN16+ KN20+ KN26+ KN30+ KN40+ Supply Sensor w/Well 02-4284 Flow Sensor (VVX15) 13-00526-002...
  • Page 50 Cast Iron Condensing Boilers – Installation Manual SERVICE AND REPLACEMENT PARTS LIST - KN6+, KN10+, KN16+, KN20+, KN26+, KN30+ and KN40+ Model Size with Item Quantities Below Name of Part Part No. KN6+ KN10+ KN16+ KN20+ KN26+ KN30+ KN40+ Conversion Kit (NG to LP) 75-00575-001 75-00575-002 75-00575-008...
  • Page 51 Cast Iron Condensing Boilers – Installation Manual SERVICE AND REPLACEMENT PARTS LIST - KN6+, KN10+, KN16+, KN20+, KN26+, KN30+ and KN40+ Model Size with Item Quantities Below Name of Part Part No. KN6+ KN10+ KN16+ KN20+ KN26+ KN30+ KN40+ Burner Rebuild Kits 75-00540-006 75-00540-005 75-00540-004...
  • Page 52 Cast Iron Condensing Boilers – Installation Manual SERVICE AND REPLACEMENT PARTS LIST - KN6+, KN10+, KN16+, KN20+, KN26+, KN30+ and KN40+ Model Size with Item Quantities Below Name of Part Part No. KN6+ KN10+ KN16+ KN20+ KN26+ KN30+ KN40+ Jacket Panel Insulation, 2" Foil Back 10-5008 Per square foot HNet V3.0 Replacement Kit...
  • Page 53 Cast Iron Condensing Boilers – Installation Manual MACODE-3 NOTICE! Commonwealth of Massachusetts Installation Requirements In the Commonwealth of Massachusetts, the (a) For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure installation must be performed by a licensed used in whole or in part for residential purposes, including plumber or gas fitter.

  • Page 54: Warranty

    Cast Iron Condensing Boilers – Installation Manual KN+ and 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 supplied boiler parts (“Products”) 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 whichever comes first.
  • Page 55 Cast Iron Condensing Boilers – Installation Manual...
  • Page 56 IN UNITED STATES: 260 NORTH ELM ST. • WESTFIELD, MA 01085 • (413) 564-5515 IN CANADA: 7555 TRANMERE DRIVE • MISSISSAUGA, ONT. L5S 1L4 • (905) 670-5888 www.knseries.com...

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