HydroTherm KN-6 Installation And Operation Instructions Manual

Cast iron condensing boilers kn series

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Installation & operating instructions manual (36 pages)

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Installation and Operation

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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. 10/12 Copyright 2010 Hydrotherm...
Page 2: Table Of Contents
DESIGNED AND TESTED ACCORDING TO A.S.M.E. MUST FOLLOW the additional instructions contained in BOILER AND PRESSURE VESSEL CODE, SECTION IV HydroTherm’s instruction sheet MACODE-3. Please FOR A MAXIMUM ALLOWABLE WORKING PRESSURE refer to the back of this manual for required regulations.
Page 3: Ratings & Capacities
4. Locate the boiler in an area that will prevent water damage to adjacent construction should a leak Direct all questions to your HydroTherm distributor or occur or during routine maintenance. contact the HydroTherm Customer Service Department at: 260 North Elm Street, Westﬁ eld, MA 01085. Always 5.
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 air option isn't used.
Page 5: General Venting Guidelines
The maximum equivalent length for the vertical intake air The KN may be vented the following ways: pipe is 80 ft, 19.7 m for KN-6, 10, 20, 120 ft, 36.6 m for 1) Direct Vent (individual venting only) (page KN-16, 26, 30. Each 90° mitered elbow and the intake 8 &...
Page 6 Category IV hangers. If any part of a single wall metal vent system conditions is 80 ft, 19.7 m for KN-6, 10, 20; passes through an unheated space it must be insulated 120 ft, 36.6 m for KN-16, 26, 30. Use Table with insulation rated for 400°F, 212°C.
Page 7 Cast Iron Condensing Boilers – Installation Manual Figure 1 - KN Series Multiple Boiler Common Venting VERTICAL CHIMNEY VENTING - When sized for a (CAT II) conﬁ guration, 1. Connect each boiler riser to the Vertical venting - multiple boiler a negative pressure of 0.02 to 0.15 in common vent with a Y or boot T.
Page 8 Cast Iron Condensing Boilers – Installation Manual Figure 2 - Horizontal Air Intake and Venting for a Single Direct Vent System Figure 3 - Horizontal Air Intake and Venting for Multiple Direct Vent Systems...
Page 9 Cast Iron Condensing Boilers – Installation Manual Figure 4 - Vertical Air Intake and Venting for Direct Vent System Figure 5 - Combination Direct Vent Systems...
Page 10 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 conﬁ guration the boiler blower is used to push the must be followed! The vent guidelines under the ﬂ...
Page 11 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 12: 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 13: General Piping Requirements
Flow Switch The ﬂ ow switch (optional on KN-6, 10, and 20; standard on KN-16, 26 and 30) is wired to prevent the boiler from ﬁ ring unless there's adequate water ﬂ ow through the unit.
Page 14: 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. Water treatment is required when ﬁ ll or General Piping Requirements make-up water contains dissolved solids greater than All heating system piping must be installed by a qualiﬁ...
Page 15 Cast Iron Condensing Boilers – Installation Manual Primary/Secondary Piping When a boiler is connected to a heating coil that may Although acceptable, the system is not as cost effective be exposed to refrigerated air from an air handling as reverse return piping. Figure 12 shows a typical device, the piping system must be equipped with ﬂ...
Page 16 Cast Iron Condensing Boilers – Installation Manual Figure 11 - Typical Multiple Boiler Reverse Return Piping (RECOMMENDED) (Careful consideration as to minimum boiler and system water ﬂ ow rates must be taken. Please consult our local manufactures representative for assistance.) Motorized Valve HIOM-11 REV .4...
Page 17: 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 head loss which will reduce ﬂ ow. Proper controls must be used to prevent water supplied for domestic use from Expansion Tank exceeding 130°F, 54°C or a scald injury will...
Page 18 Cast Iron Condensing Boilers – Installation Manual Figure 15 - Typical Multiple Boiler with Indirect Storage Tank Piping NOTES: 1. When using intermittent pump and pump delay, locate HeatNet sensor with well in lower 1/3 of tank. Install sensor with heat sensing compound. 2.
Page 19: Condensate Piping
If for any reason the boiler is not for the type of gas available at the installation site, call your HydroTherm representative to resolve the problem. Table 8 should be used to ensure that the gas supply piping is sized properly.
Page 20: Electrical Wiring
Canada. Install a separate 120 volt 15 amp circuit for from the boiler main gas valve. All boilers are each KN-6 or KN-10 boiler. Install a separate 230 volt calibrated and factory test fired at 1Ø with neutral 20 amp circuit for each KN-16, KN-20 (7 in ±...
Page 21: 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 not FOR YOUR SAFETY READ BEFORE OPERATING.
Page 22 Cast Iron Condensing Boilers – Installation Manual Operating Instructions Figure 18 - Control Panel 1. STOP! Read the safety information above. If, at any time, the appliance will not operate properly, follow the instructions “TO TURN OFF GAS TO APPLIANCE” and call your service technician or gas supplier.
Page 23 Cast Iron Condensing Boilers – Installation Manual c. Adjust low ﬁ re O2-CO2 by opening the low A high ﬁ re trim adjustment is located on the ﬁ re adjustment door located on the forward outlet ﬂ ange, (Figure 17), of the gas valve. facing side of the main gas valve, (Figure 17).
Page 24: Sequence Of Operation
Cast Iron Condensing Boilers – Installation Manual 26. Boiler allows for many modes of operation and SEQUENCE OF OPERATION control methods. Reference the "Model KN-Series Control-IOM" for instruction. NO DEMAND Standby Instructions De Mise En Marche 1. The boiler is idle with no interlocks in the fault 1.
Page 25 10.0 10.3 11.5 11.0 *See page 36 for slide damper location on KN-6, 10, 20. **Located on outlet ﬂ ange of gas valve. (Figure 17, page 20) Table 12 - Pressure Signal (P), ACTech (P45) - (Nat. Gas) KN10 KN20...
Page 26: Ignition Troubleshooting
Cast Iron Condensing Boilers – Installation Manual KN Series "Heat Net Control" Troubleshooting (Firing the KN Boiler) Variable Frequency KN Control Functions Ignition Contrrol Hand Shake Drive Ignition Sequence (Honeywell S7800) INPUTS: DISPLAY: 1. MODBUS STANDBY CALL FOR 2. AA HEAT? 3.Heat Demand 4.
Page 27: Checking & Adjustment
During the KN-10 " ignition/pilot sequence observe the lights on the KN-6 " Honeywell 7895C. The pilot light should come on but not the ﬂ ame light. If the ﬂ ame light comes on along with...
Page 28: Diagnostics
Cast Iron Condensing Boilers – Installation Manual Ignition Safety DIAGNOSTICS To test the ignition safety shutoff device, close the The KN has a display that indicates the sequence of manual shutoff valve 1 (Figure 17) in the gas supply line. operation, Figure 18.
Page 29: 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 30: Pressure Switches
Cast Iron Condensing Boilers – Installation Manual Figure 22 - KN-6, 10 and 20 Pressure Switches...
Page 31 Cast Iron Condensing Boilers – Installation Manual Figure 23 - KN-16, 26 and 30 Pressure Switches...
Page 32: Wiring
Cast Iron Condensing Boilers – Installation Manual Figure 30 - ATH Field Wiring To HeatNet Board 2.0 (KN-6, KN-10 and KN-20 only)
Page 33 Cast Iron Condensing Boilers – Installation Manual Figure 31 - ATH Field Wiring to HeatNet Board 3.0 (KN-16, KN-26 and KN-30 only)
Page 34 Cast Iron Condensing Boilers – Installation Manual AC TECH DEFAULT SETTINGS FOR HYDROTHERM KN SERIES BOILERS PARAMETER KN-6 KN-10 KN-20 KN-16, 26, 30 NAME No VFD Line Voltage used see Carrier Frequency next page Start Method for blower Stop Method...
Page 35: 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 36 Cast Iron Condensing Boilers – Installation Manual CO M BUSTI O N ANALYSIS 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 AIR BOX DIFFERENTIAL (DELTA P - WC) INCHES WC INCHES WC...
Page 37: Repair Parts
Cast Iron Condensing Boilers – Installation Manual Figure 24 - Exploded View - Front - KN-6, 10 and 20...
Page 38 Cast Iron Condensing Boilers – Installation Manual Figure 25 - Exploded View - Back - KN-6, 10 and 20...
Page 39 Cast Iron Condensing Boilers – Installation Manual SERVICE AND REPLACEMENT PARTS LIST - KN-6, KN-10 and KN-20 Model Size with Item Quantities Below Item Description Part # KN-6 KN-10 KN-20 Jacket Assembly 70-1907 70-1917 70-1927 BM-1506 Blower Assembly BM-1507 BM-1508...
Page 40 Cast Iron Condensing Boilers – Installation Manual SERVICE AND REPLACEMENT PARTS LIST - KN-6, KN-10 and KN-20 Model Size with Item Quantities Below Item Description Part # KN-6 KN-10 KN-20 Burner 70-1216 70-1215 70-1214 BM-1509 Burner Rebuild Kit BM-1510 BM-1511...
Page 41 Cast Iron Condensing Boilers – Installation Manual Figure 26 - KN-16, 26 and 30...
Page 42 Cast Iron Condensing Boilers – Installation Manual Figure 27 - KN-16, 26 and 30...
Page 43 Cast Iron Condensing Boilers – Installation Manual Figure 28 - Gas Train/Drain Pan KN-16, 26, 30 High Fire CO Adjustment Screw - Clockwise = Increase Counterclockwise = Decrease...
Page 44 Cast Iron Condensing Boilers – Installation Manual Figure 29 - Control Panel...
Page 45 Cast Iron Condensing Boilers – Installation Manual SERVICE AND REPLACEMENT PARTS LIST - KN-16, KN-26 and KN-30 Model Size with Item Quantities Below Item Description Part # KN-16 KN-26 KN-30 Supply Sensor 02-4284 Flow Switch 14-0203 30 psi Relief Valve 22-1809 22-1820 50 psi Relief Valve...
Page 46 Cast Iron Condensing Boilers – Installation Manual SERVICE AND REPLACEMENT PARTS LIST - KN-16, KN-26 and KN-30 Model Size with Item Quantities Below Item Description Part # KN-16 KN-26 KN-30 Elbow, Pilot 60-4256 Pilot Tube 10-00105-002 10-00105-001 Ignitor Block Assembly 70-1345 Electrode 04-1343...
Page 47: Installation Requirements
Cast Iron Condensing Boilers – Installation Manual MACODE-3 NOTICE! Commonwealth of Massachusetts Installation Requirements (a) For all side wall horizontally vented gas fueled In the Commonwealth of Massachusetts, the 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 ﬁ...
Page 48: Warranty
Cast Iron Condensing Boilers – Installation Manual Hydrotherm 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 (“Product”) 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 which ever comes ﬁ...

This manual is also suitable for:

Kn-10 Kn-20 Kn-26 Kn-30 Kn-16