ATH KN-40 Manual

Cast iron condensing boilers

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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. 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),

MILIMETERS [mm] or METERS [m].

Boiler Manual

Installation and Operation

Instructions

Cast Iron Condensing Boilers

Whirlwind Models

KN-6, KN-10, KN-16, KN-20,

KN-26, KN- 30 and KN- 40

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Summary of Contents for ATH KN-40

Page 1 KN-W-IOM2-0523 42-9554 Boiler Manual Installation and Operation Instructions Cast Iron Condensing Boilers Whirlwind Models KN-6, KN-10, KN-16, KN-20, KN-26, KN- 30 and KN- 40 Also read and follow: KN Control Manual 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.
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 owner should maintain a record of all service work The KN may be installed directly on 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
The maximum equivalent length for the vertical intake air 1) over public walkways; or pipe is 120 ft, 36.6 m., 100 ft, 30.5 m. (KN-40). Each 90° 2) near soffit vents or crawl spaces or other mitered elbow and the intake air cap are equal to 10 ft, 3.3 areas where condensate or vapor could m of straight pipe.
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 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 DS4FFNSAU HM-4AC No Adapter 810009369 DSD4FFNSAUK...
Page 10 Cast Iron Condensing Boilers – Installation Manual Figure 1 - KN-Series Multiple Boiler Common Venting FLUE VENT "B" DOUBLE ACTING ALL CONNECTIONS "C" BAROMETRIC DAMPER TO BE "T-WYE" "D" THERMAL SPILL SWITCH "F" VERTICAL CHIMNEY VENTING - VERTICAL VE MULTIPLE BOILER INSTALLATIONS. IT IS RECOMMENDED THAT THE BOILERS NE WHEN THE HORIZONTAL DISTANCE EXCEED WHEN SIZED FOR A (CAT II) CONFIGURATIO...
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 In this configuration the boiler blower is used to push the must be followed! The vent guidelines under the 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 vented Always provide a minimum clearance of 6 in, 152 mm 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 In order to maintain boiler capacity, increase flow rates approximately (10%) and pump head (25%) for mixtures up to 50% glycol. Improper piping of this boiler will void the manufacturer’s warranty and can cause Table 6 - Temperature Rise Table boiler failure resulting in flooding and extensive property damage!
Page 21: Heating System Piping
Cast Iron Condensing Boilers – Installation Manual HEATING SYSTEM PIPING Water Treatment This boiler was designed to operate in a closed loop heating system. System fill water must not contain more than 500 General Piping Requirements ppm of total dissolved solids and no greater than 300 ppm All heating system piping must be installed by a qualified hardness.
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 relationship between the boiler minimum output and 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.) Motorized Pump Gate Valve Valve...
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 HeatNet 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 Honeywell 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, (Figure 18a &...
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 KN-6, 10, 16, 20, 26, 30, 40 High Fire CO Adjustment Screw - percentage. Clockwise = Increase b.
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 Refer to (2015 ASHRAE Cold-Climate Buildings Design Guide) Table 12 - Pressure Signal (P) - (Nat. Gas) Standard 5:1 Turdown Option KN-6 KN-10 KN-16 KN-20 KN-26 KN-30 KN-40 Firing (Delta P) (Delta P) (Delta P) (Delta P) (Delta P) (Delta P)
Page 37: Ignition Troubleshooting
Cast Iron Condensing Boilers – Installation Manual KN- Series "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” KN-40 " Spark Gap KN-30 " The gap has to be measured and adjusted with the KN-26 "...
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 1 1/2 TO 2" LONG appropriate adjustments.
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 - KN-6, 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 - KN-6, KN-10, KN-16, KN-20, KN-26, KN-30 and KN-40 Relays, Interlocks and Boiler Status The Highest priority SYSTEM FLOW PROVE --------- Low Water Cutoff------------------- Variable Frequency Drive -------- Gas Pressure (High & Low) -----...
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: Repair Parts
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 - KN-6, 10, 16, 20, 26, 30 and 40...
Page 46 Cast Iron Condensing Boilers – Installation Manual SERVICE AND REPLACEMENT PARTS LIST - KN-6, KN-10, KN-16, KN-20, KN-26, KN-30 and KN-40 Model Size with Item Quantities Below Name of Part Part No. KN-6 KN-10 KN-16 KN-20 KN-26 KN-30 KN-40 Supply Sensor w/Well...
Page 47 Cast Iron Condensing Boilers – Installation Manual SERVICE AND REPLACEMENT PARTS LIST - KN-6, KN-10, KN-16, KN-20, KN-26, KN-30 and KN-40 Model Size with Item Quantities Below Name of Part Part No. KN-6 KN-10 KN-16 KN-20 KN-26 KN-30 KN-40 Conversion Kit (LP to NG)
Page 48 Cast Iron Condensing Boilers – Installation Manual SERVICE AND REPLACEMENT PARTS LIST - KN-6, KN-10, KN-16, KN-20, KN-26, KN-30 and KN-40 Model Size with Item Quantities Below Name of Part Part No. KN-6 KN-10 KN-16 KN-20 KN-26 KN-30 KN-40 Combustion Chamber...
Page 49 Cast Iron Condensing Boilers – Installation Manual SERVICE AND REPLACEMENT PARTS LIST - KN-6, KN-10, KN-16, KN-20, KN-26, KN-30 and KN-40 Model Size with Item Quantities Below Name of Part Part No. KN-6 KN-10 KN-16 KN-20 KN-26 KN-30 KN-40 Ignition Transformer...
Page 50 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 51: 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 52 IN UNITED STATES: 260 NORTH ELM ST. • WESTFIELD, MA 01085 • (833) 265-5371 IN CANADA: 7555 TRANMERE DRIVE • MISSISSAUGA, ONT. L5S 1L4 • (905) 670-5888 www.knseries.com...

This manual is also suitable for:

Kn-6 Kn-10 Kn-16 Kn-20 Kn-26 Kn-30 ... Show all