HydroTherm KN-2 Installation And Operation Instructions Manual

Cast iron condensing boilers kn series

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Manual (88 pages)

User manual (48 pages)

Control manual (32 pages)

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See also: User Manual , Instruction and Installation Manual

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.

Cast iron condensing boilers

Models K N-2 and K N-4

Boiler manual

Installation and operation

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Summary of Contents for HydroTherm KN-2

Page 1: Installation And Operation
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. P/N 42-9450 8/08 Copyright 2008 Hydrotherm...
Page 2 Cast iron heat exchanger Th e K N cast iron heat exchanger uses Hydrotherm’ s graphite port seals and ground joint fi t-up between sections for maximum fl exibility and resistance to thermal expansion. Th e heat exchanger provides maxi- mum heat transfer with its counterfl ow design and fl ow-controlling baffl e assembly.
Page 3 KN INSTALLATION AND OPERATION INSTRUCTIONS Page 3 The Hydrotherm K N condensing cast iron boiler Components Gas valve Pressure/temperature gauge Jacket Cast iron section assembly K N-2 Inlet air fi lter access panel Blower K N HeatNet control with keypad and display...
Page 4: Table Of Contents
Customer service and technical support Please direct all questions to your Hydrotherm distributor or contact the Hydrotherm Customer Service Department at: 260 North Elm Street Westfi eld, MA 01085 Start-up/service history...
Page 5: Read Before Beginning The Installation
Combustion analyzer — You must use a combustion analyzer and follow you MUST FOLLOW the additional instructions contained in Hydrotherm’ s instruction sheet, MA CODE. If you don’t have a all instructions in this manual to correctly start-up the boiler. As prescribed copy, call your Hydrotherm dealer or Hydrotherm.
Page 6: Boiler Ratings And Specifi Cations
Th ermostat anticipator sett ing is for a single thermostat connected to a single K N boiler. Also jumper from the Heat Demand terminals to the IAR1 terminals on the connection board. See the K N Control manual for details. P/N 42-9450 8/08 Copyright 2008 Hydrotherm...
Page 7: Installation Site Preparation
Adjacent construction Hydrotherm. Where cleaning is not possible, the boiler may have to be replaced. • Locate the boiler in an area that will prevent water damage to adjacent construction should a leak occur or •...
Page 8: Clearance Requirements
Make sure that the installation allows serviceman access to the left side for this purpose. Table 2 Recommended minimum clearances for service/operation (Figure 2) From: Inches Millimeters Back Left side Right side Front Rear P/N 42-9450 8/08 Copyright 2008 Hydrotherm...
Page 9: Combustion Air Requirements
Figure 2, and the top of the opening is within 12 inches of the ceiling. Size the opening to provide minimum free area of: of all K N boilers in the room. 1 in per 3,000 BTUH P/N 42-9450 8/08 Copyright 2008 Hydrotherm...
Page 10: Prepare The Boiler
Install a shut-off valve in the boiler supply and return connections to allow isolation of the boiler for servicing when necessary. P/N 42-9450 8/08 Copyright 2008 Hydrotherm...
Page 11: Water Piping
For ASME CSD-1 or Canadian applications, or when required by applicable codes, postpurge circulator includes an integral check valve to prevent by-pass fl ow during operation. install an additional high limit control in the supply piping above the boiler. P/N 42-9450 8/08 Copyright 2008 Hydrotherm...
Page 12 Also consider installing a water meter on the cold water make-up line. Th e water Th is will lead to section failure due to oxygen meter will show if excessive make-up water is entering the system. corrosion and lime deposits. P/N 42-9450 8/08 Copyright 2008 Hydrotherm...
Page 13: Zoning With Zone Valves
Purge valve — Suggested locations allow for improved 12 Extra high limit (when required) DHW circulator system fi lling and draining and initial air elimination. 13 Zone valve Flow/check valve Cold water fi ll line 14 Zone circulator Temperature gauge P/N 42-9450 8/08 Copyright 2008 Hydrotherm...
Page 14 Indirect-fi red DHW tank systems.) (when used) Temperature gauge 11 Low water cut-off (when required) DHW circulator 12 Extra high limit (when required) Flow/check valve Cold water fi ll line 14 Zone circulator P/N 42-9450 8/08 Copyright 2008 Hydrotherm...
Page 15 10 Air separator with automatic air vent (Replace air vent Indirect-fi red DHW tank with piping to the tank fi tt ing on closed-type expansion (when used) systems.) DHW circulator 11 Low water cut-off (when required) P/N 42-9450 8/08 Copyright 2008 Hydrotherm...
Page 16 10 Air separator with automatic air vent (Replace air vent Indirect-fi red DHW tank with piping to the tank fi tt ing on closed-type expansion Isolation valve (when used) systems.) DHW circulator 11 Low water cut-off (when required) Temperature gauge P/N 42-9450 8/08 Copyright 2008 Hydrotherm...
Page 17: Chilled Water Systems
Figure 13 Suggested piping — boilers connected to chilled water systems P/N 42-9450 8/08 Copyright 2008 Hydrotherm...
Page 18: Gas Piping
If for any reason the boiler is not for the type of gas avail- Item 4 — Install a ground-joint union in the gas line for ease of installation and servicing. able at the installation site, call your Hydrotherm representative to resolve the problem. (See WARNING below.) Item 5 —...
Page 19 Replace the cover aft er completing the death or substantial property damage. gas connection inspection and testing. P/N 42-9450 8/08 Copyright 2008 Hydrotherm...
Page 20: Wiring A Single Boiler
See Figures 15 and 16. • Connect minimum 14awg copper wire to the power connection as shown in Figure 16. • Install a fused service switch, mounted and installed in accordance with all applicable codes. P/N 42-9450 8/08 Copyright 2008 Hydrotherm...
Page 21: Boiler Circulator
Figure 17 Wiring the boiler circulator using a circulator relay (required for motors over 1/4 hp) Figure 18 Wiring the boiler circulator using a relay or starter (required for motors over 1/4 hp) (KN-2 only) P/N 42-9450 8/08 Copyright 2008 Hydrotherm...
Page 22 Th e circulator used for DHW must be operated by a circulator relay or zone controller that is activated when the tank aquastat calls for heat. • Connect the tank aquastat terminals across the DHW DEMAND terminals on the electrical connection board as shown in Figure 21. P/N 42-9450 8/08 Copyright 2008 Hydrotherm...
Page 23: Control Setup
KN INSTALLATION AND OPERATION INSTRUCTIONS Page 23 Wiring and control setup (continued) Figure 21a wiring summary (see Boiler manual and Control manual text for additional information) Also see page 20 P/N 42-9450 8/08 Copyright 2008 Hydrotherm...
Page 24 Wiring and control setup (continued) Figure 21b wiring summary (see Figure 21 for locations) (see Boiler manual and Control manual text for additional information) Also see page 21 Also see page 22 (KN-2 only) P/N 42-9450 8/08 Copyright 2008 Hydrotherm...
Page 25: Control Setup
7. Continuing to press the DOWN key will access these menu options: • BOILERS • SETPOINTS • INDOOR AIR • PUMP OPTIONS • NIGHT SETBACK • OPTIONS • LOG/RUNTIME • AUX FUNCTIONS • SYSTEM CLOCK • ADVANCED SETUP P/N 42-9450 8/08 Copyright 2008 Hydrotherm...
Page 26 Press SELECT to enter the indoor air menus. Skip this procedure if the boiler is not used for DHW heating. Use the arrow keys until the cursor is at DHW SETPT. Th e display will be: Th e display will show: P/N 42-9450 8/08 Copyright 2008 Hydrotherm...
Page 27 STANDBY. Then turn off power and the boiler on/off To set outdoor reset operation, use the arrow keys until the cursor points at OA switch. Reconnect HEAT DEMAND and RESET. DHW DEMAND wires. P/N 42-9450 8/08 Copyright 2008 Hydrotherm...
Page 28: Vent Piping (And Air Piping When Used)
étré modifi é pour respecter les valeurs NFPA 54 and or CSA B149 Installation Codes. minimales des tableaux pertinents de l’appendice F du Na- tional Fuel Gas Code, ANSI Z223.1/NFPA 54 et (ou) des codes d’installation CSA-B149. P/N 42-9450 8/08 Copyright 2008 Hydrotherm...
Page 29: Condensate Drain Line
Wire the switch into the boiler limit circuit. See the K N Control manual for details. Neutralization When required by codes or preference, install an appropriate condensate neutralization system. P/N 42-9450 8/08 Copyright 2008 Hydrotherm...
Page 30: Fill And Test The System
If required, make isolation valves in the system. sure that the owner is aware and that the regimen will be continued. • Flush until the water runs clean. P/N 42-9450 8/08 Copyright 2008 Hydrotherm...
Page 31: System Pressure
Watch the boiler pressure/temperature gauge throughout substantial property damage. the start-up process. Make sure the pressure never drops below 12 psig and never goes higher than 80% of the boiler relief valve sett ing pressure. P/N 42-9450 8/08 Copyright 2008 Hydrotherm...
Page 32: Starting The Boiler
Th is would destroy the gas valve, rendering it unusable. • Check air inlet termination to be sure it is correct and not obstructed. P/N 42-9450 8/08 Copyright 2008 Hydrotherm...
Page 33: Operating Instructions
Check for leaks, if not already done, • If none of the above resolve the problem, follow the trouble- following the instructions on page 18. shooting guide in the K N Control manual. P/N 42-9450 8/08 Copyright 2008 Hydrotherm...
Page 34 ON at purge RPM for postpurge Normal display unless ignition is unsuccessful three times after Boiler restarts a normal sequence restart For more information: See the KN Control manual for additional information and troubleshooting. P/N 42-9450 8/08 Copyright 2008 Hydrotherm...
Page 35: For Your Safety Read Before Operating
1. Set the thermostat to its lowest setting. 3. Turn manual gas valve handle clockwise CLOSE DO NOT FORCE THE HANDLE. 2. Turn off all electric power to the boiler if service is to be performed. 42-5230 P/N 42-9450 8/08 Copyright 2008 Hydrotherm...
Page 36 Page 36 KN INSTALLATION AND OPERATION INSTRUCTIONS Starting the boiler (continued) Illustration 26 En francaise . . . P/N 42-9450 8/08 Copyright 2008 Hydrotherm...
Page 37 (see page 38). 6. Check the analyzer. A rapid increase in CO is an indicator of bad combustion. Turn the boiler and reduce fuel input as explained on page 38. P/N 42-9450 8/08 Copyright 2008 Hydrotherm...
Page 38 7. If the computed rate exceeds the desired input rate or 200,000 Btuh, reduce the gas adjustment must be changed using the procedure input with the gas thrott le adjustment. on page 39. P/N 42-9450 8/08 Copyright 2008 Hydrotherm...
Page 39 Pull the air fi lter clamp back. Replace the fi lter, gasket and access cover. Secure with the three thumbscrews. Replace the gas valve cover plate if removed. Remove the low-fi re jumper from the connection board. Replace the electrical panel cover. P/N 42-9450 8/08 Copyright 2008 Hydrotherm...
Page 40 Test HeatNet operating limit function Allow the boiler to fi re until the supply temperature reaches the upper end of the Complete the checklist and installation certifi cate on the control band. back page of this manual. P/N 42-9450 8/08 Copyright 2008 Hydrotherm...
Page 41: Annual Start-Up
Make sure that all maintenance procedures are being exchanger is damaged or blocked with debris, followed and that all instructions are clear and understood. consult the factory for corrective action. Operating the boiler with a damaged or P/N 42-9450 8/08 Copyright 2008 Hydrotherm...
Page 42: Maintenance
If problems can’t be resolved • Eye exposure — irrigate immediately If following the procedures in the K N manuals do not resolve problems, contact Hydrotherm for technical support to resolve the issues. • Breathing — fresh air. P/N 42-9450 8/08 Copyright 2008 Hydrotherm...
Page 43 Th e combustion chamber operates with a positive pressure. Failure to comply could result in severe personal injury, death or substantial property damage. P/N 42-9450 8/08 Copyright 2008 Hydrotherm...
Page 44 RTV .) 12. Look down into the section assembly to verify it is clean. If the heat exchanger is blocked with sediment or shows damage, contact Hydrotherm immediately for Figure 37 Burner and chamber corrective action.
Page 45 KN INSTALLATION AND OPERATION INSTRUCTIONS Page 45 Maintenance (continued) Notes P/N 42-9450 8/08 Copyright 2008 Hydrotherm...
Page 46: Replacement Parts
100 WATT AMETEK BLOWER 70-1237 FILTER BOX ADAPTER 57-3413 #6 X 1/2” BLK OXIDE SCREW 57-2913 1/4-20 X 1 NYLOK SC HD CAP SCREW 03-1759 BUTTON GUARD 54-3234 1/2” FLEX GAS LINE 70-1422 REMOVABLE BOILER CONTROL P/N 42-9450 8/08 Copyright 2008 Hydrotherm...
Page 47 KN INSTALLATION AND OPERATION INSTRUCTIONS Page 47 K N-2 Replacement parts (continued) P/N 42-9450 8/08 Copyright 2008 Hydrotherm...
Page 48 Page 48 KN INSTALLATION AND OPERATION INSTRUCTIONS K N-4 Replacement parts P/N 42-9450 8/08 Copyright 2008 Hydrotherm...
Page 49 KN INSTALLATION AND OPERATION INSTRUCTIONS Page 49 K N-4 Replacement parts (continued) P/N 42-9450 8/08 Copyright 2008 Hydrotherm...
Page 50 3/4 NPT X CLOSE NIPPLE 02-4279 COMMUNICATIONS BOARD 22-1203 3-4 X 3-4 F TO F 30 PSI 535K BTU 02-4276 IGNITION CONTROL PER HOUR RELIEF VALVE 02-1510 PRESSURE SWITCH 45-1272 CERAMIC CHAMBER 59-1096 CERAMIC CHAMBER GASKET P/N 42-9450 8/08 Copyright 2008 Hydrotherm...
Page 51: Appendix A - Suggested Wiring
Th is is because these terminals are jumpered internally on the electrical connection board. If there is more than one transformer, provide one wire from each transformer common side to one of the negative terminals ( IAR – P/N 42-9450 8/08 Copyright 2008 Hydrotherm...
Page 52 Before connecting Verify 24VAC switched lead from thermostat: the wires to the IAR terminals, use a voltmeter to verify the 24VAC hot lead is NOT powered when the thermostat is not calling for heat. P/N 42-9450 8/08 Copyright 2008 Hydrotherm...
Page 53 DHW tank aquastat and circulator. Th e priority switch will turn off space heating when there is a DHW call. Read the controller manufacturer’ s instructions to determine which zone is set up for priority operation. P/N 42-9450 8/08 Copyright 2008 Hydrotherm...
Page 54 Figure A3 Indoor Air Reset wiring to IAR terminals, Heat Demand and DHW Demand using typical zone controller for either circulators or zone valves (see Figure 21a for terminal block 2 and 6 locations) P/N 42-9450 8/08 Copyright 2008 Hydrotherm...
Page 55 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 P/N 42-9450 8/08 Copyright 2008 Hydrotherm...
Page 56 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...

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