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ATH KN-10 Assembly Instructions Manual

Gas-fired cast iron boilers
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See also: Control 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.
Gas-Fired Cast Iron Boilers
Models K N-6, -10, -16, -20,
-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-FAI2-0814
8/14 Copyright 2010 Advanced Thermal Hydronics
42-9552

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Summary of Contents for ATH KN-10

  • Page 1: Field Assembly

    KN-FAI2-0814 42-9552 Gas-Fired Cast Iron Boilers Models K N-6, -10, -16, -20, -26, and - 30 Field Assembly Instructions Also read and follow: KN Series Gas Boiler Installation and Operating Instructions KN HeatNet Control 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.

  • Page 2: Read Before Proceeding

    Gas-Fired Direct Vent Cast Iron Boilers – Field Assembly Instructions INFORMATION READ BEFORE PROCEEDING This manual is intended only for the fi eld assembly of a KN-6, -10, -16, -20, -26 or -30 boiler. Follow the Customer Service And Technical Support assembly instructions in sequence.
  • Page 3 Gas-Fired Direct Vent Cast Iron Boilers – Field Assembly Instructions ATTENTION: COMPONENTS AND SPECIAL TOOLS REQUIRED Use of an approved dust respirator is strongly recommended when handling the Recommended Assembly Crew insulating components of the boiler. The assembly crew should be a minimum of Electrical shock hazard —...

  • 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.

  • Page 12: Outlet Manifold

    Gas-Fired Direct Vent Cast Iron Boilers – Field Assembly Instructions Step 24 Apply jacket rear insulation and jacket rear panel (temporarily) and install supply and return manifolds Use of an approved dust respirator is strongly recommended when handling the insulating components of the boiler. 1.
  • 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.

  • 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, and connect wiring 1. Remove the covers on the blower housing. 2. Connect wires from blower housing components to control panel. Step 40 Adjust the ignition electrode/UV scanner assembly and install 1.
  • 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.

  • 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) 670-5888 • FAX (905) 670-5782 www.knseries.com...

This manual is also suitable for:

Kn-16Kn-20Kn-6Kn-26Kn-30

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