Hydrotherm

®

KN

-Series

Gas-fired direct vent Cast iron boilers Model KN-20 only

Field assembly instructions Also read and follow:

KN Series Gas Boiler Installation & Operating Instructions and KN HeatNet 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. Install, start and service the boiler only in the sequence and methods given in this manual and the documents listed above. Failure to do so can result in severe personal injury, death or substantial property damage. Do not use the boiler during construction. Construction dust and particulate, particularly drywall dust, will cause contamination of 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. P/N 42-9551 Copyright 2011 Mestek, Inc.

KN Series Gas-fired direct vent cast iron boilers – Field assembly instructions

Contents and information Read before beginning the installation . . . . . . . . 5 Boiler ratings and specifications . . . . . . . . . . . . 6 Installation site preparation . . . . . . . . . . . . . . . 7

Hazard icons You will find the following icons throughout this manual. (English/French)

Prepare the boiler . . . . . . . . . . . . . . . . . . . . . 10

Water piping . . . . . . . . . . . . . . . . . . . . . . . . 11 Gas piping . . . . . . . . . . . . . . . . . . . . . . . . . 18 Wiring a single boiler . . . . . . . . . . . . . . . . . . 20 Control setup . . . . . . . . . . . . . . . . . . . . . . . 25

The WARNING icon indicates a hazard that can cause severe personal injury, death or substantial property damage.

The CAUTION icon indicates a hazard that will or can cause minor personal or property damage.

Vent piping (and air piping when used) . . . . . . . 28

Condensate drain line . . . . . . . . . . . . . . . . . . 29 Fill and test the system . . . . . . . . . . . . . . . . . 30 Starting the boiler . . . . . . . . . . . . . . . . . . . . 32

The NOTICE icon calls out special instructions that are important, but are not related to hazards.

Other manuals

Annual start-up . . . . . . . . . . . . . . . . . . . . . . 41 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 42 Replacement parts . . . . . . . . . . . . . . . . . . . . 46 Appendix A — suggested wiring . . . . . . . . . . . 48

You must read and follow this manual, the KN Series Gas Boiler Installation and Operating Instructions, the KN HeatNet Control manual and all additional materials supplied with the boiler. Failure to do so can result in severe personal injury, death or substantial property damage.

Boiler/control installation and setup After completing assembly of the KN boiler, follow all instructions in the Installation and Operation Instructions and Control Manual for installation, start-up and testing. 2

P/N 42-9551

KN Series Gas-fired direct vent cast iron boilers – Field assembly instructions

Read before proceeding

Customer service and technical support Direct all questions to your HydroTherm distributor or contact the HydroTherm Customer Service Department at: 260 North Elm Street Westfield, MA 01085. Always include the model and serial numbers from the rating plate of the boiler in question. Claims for damage or missing components must be filed immediately against the transportation company by the consignee.

Codes and standards

Attention:

Code compliances

Use of an approved dust respirator is strongly

All aspects of the boiler installation must conform to the requirements of the authority having jurisdiction, or, in the absence of such requirements, to the National Fuel Gas Code, ANSI Z223.1/NFPA 54-latest revision. Where required by the authority having jurisdiction, the installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1.

Electrical shock hazard — Disconnect all electrical power sources to the boiler before making any electrical connections.

In Canada, the installation must be in accordance with the requirements of CSA B149.1 or .2, Installation Code for Gas Burning Appliances and Equipment.

recommended when handling the insulating components of the boiler.



Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation! Verify proper operation after servicing.



Failure to comply with the above could result in severe personal injury, death or substantial property damage.

Before assembling the boiler . . .

The electrical connections to this boiler must be made in accordance with all applicable local codes and the latest revision of the National Electrical Code, ANSI /NFPA-70. Installation should also conform to CSA C22.1 Canadian Electrical Code Part I if installed in Canada. Install a separate 120 volt 15 amp circuit for the boiler. A properly rated shut-off switch should be located at the boiler. The boiler must be grounded in accordance with the authority having jurisdiction, or if none, the latest revision of the National Electrical Code, ANSI/NFPA-70.

Verify boiler rating and gas supply • Before assembling and installing the boiler, check the ratings to ensure that the unit has been sized properly for the job. • Ensure that the boiler will be set up for the type of gas available at the installation site.

Verify location is suitable



• Ensure the availability of an adequate electrical supply, uncontaminated air for combustion, and that vent (and air) piping can be correctly installed. • Ensure the boiler can be connected to system water piping and gas supply.

DO NOT open any gas valve, or attempt to fire the boiler, until all boilers have been set up and verified following the instructions in the KN Series Gas Boiler Installation & Operating Instructions.

• The boiler must not be exposed to dripping or spraying water or to rain. • If replacing an existing boiler, find out what caused the boiler to fail before installing a new boiler. Correct the problems that led to failure, or the failure may happen to the new boiler.

P/N 42-9551

Line voltage field wiring of any controls or other devices must use copper conductors with a minimum size of #14 awg. Use appropriate wiring materials for units installed outdoors.



Failure to comply could cause a boiler failure, leading to possible severe personal injury, death or substantial property damage.

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KN Series Gas-fired direct vent cast iron boilers – Field assembly instructions

Components and special tools required Special equipment/materials required for assembly 1. One quart 30-wt motor oil

5. Two 18-inch pipe wrenches

2. Rubber and leather gloves

6. Torque wrench (at least 30 foot-pound capacity)

3. Rubber or leather mallet 4. Two 2”x4”x12” boards (used for cushioning when seating push nipples)

7. Deep socket, 11/16” for use with torque wrench

8. Standard hand tools, wire, nuts, electrical hand tools 9. 2”x2” steel square stock x 6 inches long, for driving square-socket pipe plugs (supplied with boiler in hardware box)

Sealants, lubricants and adhesives supplied with boiler (in hardware box) Use gloves when working with these products as specified in these instructions and in the product instructions.

1. Silicone RTV-6500 HiTemp: (3) 10oz caulk tubes (for sealing between sections) 2. Loc-Tite 30557 pipe dope: (1) 16-oz can (for water and gas piping connections) 3. Hercules Pro Dope: (1) 8-oz jar (for

mixing with 30-wt motor oil, used as lubricant for push nipples) 4. Res Bond 2300: (1) 11-oz caulk tube (for sealing burner assembly) 5. Fast-Tack 87: (1) 13-oz spray can (for securing flue baffles to sections)

Boiler components and shipping information Skid 1

Skid 2

Skid 3

Cast iron sections (front, rear and intermediate)

Base

Jacket components

Burner kit

Jacket insulation

Push nipples

Ceramic combustion chamber

Blower and filter box assembly

3” x 8” supply nipple and return nipple

Drain pan (with inspection cover plate pre-attached)

Control box assembly

Pipe plugs

Upper casting

Draw rods and hardware

Gas train shroud

4” x 6” boards for section assembly

Components box (igniter, sight glass, supply and return sensors, LWCO assembly, etc.)

All-thread rods (7/8”) and cast-iron draw-up plates for assembling boiler block Ceramic flue baffles Hardware box (bolts, nuts, etc., individually packed/labeled by usage)

4

Gas train assembly

Flue adapter assembly Condensate trap assembly

P/N 42-9551

KN Series Gas-fired direct vent cast iron boilers – Field assembly instructions

Step 1 Place 4x6 boards on base Ignore the palette under the boiler in the manual images — it is left in place during assembly for demonstration purposes only.

1. Remove base from skid. 2. Place a 4x6 board (supplied) against each side as a runner shown. 3. Space runner boards with about even amounts off of each end of the base. 4. The runner boards will be used to support the boiler block during assembly, then removed afterward.

Step 2 Oil top surface of runner boards 1. Use a brush to spread 30-wt motor oil on the runner boards. This will allow sections to move easily during draw-up.

Step 3 Position the rear section Use leather gloves when lifting or moving boiler sections. Sections are heavy and can cause severe personal injury or death if mishandled.

1. Identify the rear section — its lower nipple port is on the right side when looking at the inside of the section, as in this photo. 2. Slide the rear section to the end of the base. Have someone support the section during the next step.

Lift section using two people, following the recommendations shown in Step 13, page 8.

Step 4 Bolt rear section to base 1. Use 3/8 x 3½” bolts, wedges, split lock washer and nut on each side as shown. 2. Point the wedge narrow edge toward the section.

P/N 42-9551

Tighten bolt firmly, but DO NOT over-tighten — the cast iron flange could be broken if too tight. Tighten only until the split lock washer has just flattened.

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KN Series Gas-fired direct vent cast iron boilers – Field assembly instructions

Step 5 Prepare section for baffle Use of an approved dust respirator is strongly recommended when handling the insulating components of the boiler.

1. Spray cast iron heat pin section liberally with spray adhesive supplied with the boiler. 2. Avoid spraying on the nipple port machined surfaces.

Step 6 Install baffle Do not use baffles if they have been broken, cracked, folded or frayed. Obtain replacements before proceeding with the boiler assembly.

1. Place a baffle in the heat pin area of the front section as shown. 2. The cut-off corner must go to the lower right. 3. Press into place. 4. Make sure the baffle does NOT overlap onto the perimeter surfaces of the section. This would prevent the section from drawing up correctly.

Step 7 Apply RTV to perimeter Rubber gloves are recommended for this procedure.

1. Apply a bead of silicone RTV (supplied with boiler) on the perimeter surfaces of the section and around the INSIDE edges of the nipple ports. 2. This is necessary to form a seal between the sections. The seal prevents flue gases from escaping. 3. Extend the bead all the way from the top of the section to the bottom. 4. Keep the bead of silicone close to the INSIDE edge of the nipple ports. 5. This will protect the machined nipple port surfaces from condensation that may occur in the flueways.

6

P/N 42-9551

KN Series Gas-fired direct vent cast iron boilers – Field assembly instructions

Step 8 Push nipple lubricant Rubber gloves are recommended for this procedure.

1. In a disposable container, mix some 30-wt motor oil with some of the Hercules Pro Dope supplied with the boiler. 2. The consistency should be similar to thick paint and should flow easily. 3. You will need enough to lubricate all nipple ports and all push nipples — probably about ½ pint is enough.

Step 9 Lubricate nipple ports 1. Brush the pipe dope/oil mixture on the inner machined surfaces of the nipple ports. 2. Avoid getting lubricant on the silicone RTV or on the face of the nipple ports.

Step 10 Lubricate push nipples 1. Brush the entire outside surface of each nipple port with the lubricant.

Step 11 Insert push nipples Avoid scarring or damaging the push nipple or nipple port surfaces. The push nipple makes a metal-to-metal seal with the nipple port. Any surface defects could cause a leak.

P/N 42-9551

1. Insert a push nipple into each of the two nipple ports. 2. Seat each nipple firmly but squarely. 3. Make sure the nipple face is parallel to the section surface as closely as possible. 4. DO NOT attempt to assemble sections if any nipple port is mis-aligned.

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KN Series Gas-fired direct vent cast iron boilers – Field assembly instructions

Step 12 Seat the push nipples 1. Place a 2x4 board across the nipple and strike firmly with a mallet. 2. Do this with several strokes, just so the push nipple is firmly started. 3. Make sure the board is parallel to the nipple port surface to prevent rolling the push nipple.

Step 13 Lifting the sections Use leather gloves when lifting or moving boiler sections. Sections are heavy and can cause severe personal injury or death if mishandled.

1. Lift section, with each person holding at the bottom of the section. 2. Handlers should lift with their legs to avoid back strain.

Lift section using two people, following the recommendations shown in Step 13, page 8.

Step 14 Draw up sections 1. Carefully slide the first intermediate section up to the front. 2. Before pulling the intermediate section up fully, brush lubricant on the inside machined surfaces of the nipple ports as in Step 9, page 7. 3. Use a 2x4 board and mallet to start the section in place as shown in Step 17, page 9.

4. Wipe a small amount of motor oil on the ¾-inch all-thread rods supplied with the boiler to make pull-up easier. 5. Place a ¾” nut and washer plus a cast iron plate (supplied with boiler) on the ¾” rod on each side as shown. 6. Snug finger tight.

Step 15 Pull sections together 1. Use box wrenches (preferred) to pull the sections together. 2. Alternate from one side to the other during pull-up to avoid cocking the nipple ports. 3. When the sections are properly pulled up, they will be nearly metalto-metal.

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P/N 42-9551

KN Series Gas-fired direct vent cast iron boilers – Field assembly instructions

Step 16 Install baffle Do not use baffles if they have been broken, cracked, folded or frayed. Obtain replacements before proceeding with the boiler assembly.

1. Before adding additional sections, install a baffle in the flueway as in Step 5, page 6 and Step 6, page 6. 2. Place a baffle in the heat pin area of the front section as shown. 3. The cut-off corner must go to the lower right. 4. Press into place. 5. Make sure the baffle does NOT overlap onto the perimeter surfaces of the section. This would prevent the section from drawing up correctly.

Step 17 Use 2x4 and mallet 1. To initially seat the push nipple into the next section, rap with a mallet and 2x4 at each nipple port. 2. Repeat, alternating from right nipple port to left to avoid cocking the push nipples.

Step 18 Install draw rods The draw rods ARE NOT used to pull the sections together, only to keep them firmly in position.

1. When the section assembly is completed, slide a draw rod through each of the four draw rod holes. 2. Apply a washer and nut on each end and pull up finger tight.

Step 19 Use a torque wrench DO NOT exceed 30 footpounds when tightening nuts. Higher torque could cause breakage of the cast iron.

1. Use a torque wrench to tighten the nuts on the draw rods. 2. Start with the upper left corner rod first. 3. Tighten the nut to 15 foot-pounds. 4. Move to the lower right rod. Tighten the nut to 15 foot-pounds. 5. Repeat with the lower left, then the upper right rod, both tightened to 15 foot pounds. 6. Repeat this sequence again, but finish the tightening to 30 foot-pounds for each nut.

P/N 42-9551

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KN Series Gas-fired direct vent cast iron boilers – Field assembly instructions

Step 20 Bolt boiler to base Before bolting the boiler to the base, knock the two 4x6 boards out from under the block. If necessary, loosen the two bolts that secure the back section to the base.

1. Install a bolt, wedge, washer and nut on side of the front section as done in Step 4, page 5. 2. Tighten only until the split lock washer has just flattened. 3. Make sure the back section bolts are tightened as well.

Step 21 Inspection port plugs 1. Apply pipe dope (supplied with boiler) to plugs (supplied) and install in each of the inspection ports at the lower right side of each section.

Step 22 Prepare condensate pan Rubber gloves are recommended for this procedure. The condensate drain pan is shown here with the inspection plate and gasket installed. This can be done before or after the condensate drain pan is bolted to the boiler.

1. Use the silicone RTV supplied with the boiler to apply a bead on the condensate pan flange around the complete perimeter. 2. At each of the four corners, apply a bead on the flange where the sheet metal edges meet.

Step 23 Install condensate drain pan 1. This procedure requires two people to do correctly. 2. Guide the condensate drain pan through the front of the base as shown.

4. Install each bolt with two flat washers, one split lock washer and nut (provided). Insert the bolts from the top. 5. Tighten just until the split lock washer has flattened.

3. When in position, lift the pan straight up and hold firmly against the bottom of the section assembly.

10

P/N 42-9551

KN Series Gas-fired direct vent cast iron boilers – Field assembly instructions

Step 24 Install condensate drain connector The condensate drain pan is shown here without the inspection plate and gasket installed, to be installed in Step 25, page 11.

1. The condensate drain connector consists of a plate, O-ring and strainer.

See Step 25, page 11 for details of condensate drain pan components.

4. Look for underneath while assembling to ensure the condensate drain connector is properly seated.

2. Assemble the three parts as shown. 3. Insert the assembly into the bottom of the condensate drain pan.

5. Secure in place with the screws provided.

Step 25 Install inspection cover This could be done before the condensate drain pan is installed, as shown in Step 22, page 10.

LEGEND for drawing at right:

The inspection cover is used for annual inspection of the section assembly and condensate handling components.

32 Inspection cover gasket

1. Assemble inspection cover flange and gasket. 2. Position over condensate drain pan inspection opening.

30 Hex nuts 31 Inspection cover 33 Condensate drain pan 34 Condensate strainer 35 Condensate drain connector O-ring 36 Condensate drain connector plate 37 Washers 38 Hex bolts

3. Secure with screws provided.

Step 26 Inspect combustion chamber area for excess silicone

1. Remove any excess silicone that may have extruded into the interior of the section assembly. 2. This area must not have any blockage where the combustion chamber will be inserted.

P/N 42-9551

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KN Series Gas-fired direct vent cast iron boilers – Field assembly instructions

Step 27 Install combustion chamber The combustion chamber material is fragile, and can be cracked or gouged with incorrect handling. HANDLE CAREFULLY! DO NOT use the chamber if it is damaged. Use of an approved dust respirator is strongly recommended when handling the insulating components of the boiler.

1. Insert the chamber into the top of the section assembly as shown. 2. Position the chamber with the ROUND hole toward the front and the SQUARE hole to the rear. 3. The combustion chamber should sit evenly in the opening, with its FLAT surface facing up and even with the surface of the sections.

Step 28 Position the burner gasket Use of an approved dust respirator is strongly recommended when handling the insulating components of the boiler.

1. Carefully place the burner gasket on the surface of the combustion chamber.

Step 29 Apply Resbond adhesive to the burner gasket Rubber gloves are recommended for this procedure.

1. Apply a generous bead of Resbond adhesive (supplied with boiler) around the entire burner gasket. 2. Position the bead in the center of the gasket. 3. This adhesive will bond the gasket to the burner when the burner is installed.

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P/N 42-9551

KN Series Gas-fired direct vent cast iron boilers – Field assembly instructions

Step 30 Burner and manifold REMOVE THE PILOT ORIFICE ASSEMBLY before proceeding. The pilot orifice assembly (shown in Step 37, page 15) is factoryinstalled in the manifold. It must be removed before the manifold is installed to prevent damage to the pilot assembly or pilot tube.

Step 31 Apply silicone RTV to top surface of section assembly Rubber gloves are recommended for this procedure.

1. This illustration shows the manifold (left) and the burner (right). 2. Orient the burner as shown, with the double set of bolt notches on the same side as the blower flange of the manifold. 3. This will position the pilot tube at the top as shown in the lower photo.

1. Apply a generous bead of silicone RTV completely around the flange surface of the section assembly.

Step 32 Mark bolt locations 1. Some of the bolt notches in the burner flange will be used to secure the manifold. 2. The burner is attached to the section assembly before the manifold. To avoid using the wrong bolt notches, place the burner against the manifold as shown. 3. Use a marker pen to mark ONLY the bolt notches NOT required for bolting the manifold.

P/N 42-9551

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KN Series Gas-fired direct vent cast iron boilers – Field assembly instructions

Step 33 Install the burner 1. Place the burner on top of the section assembly as shown. 2. The PILOT TUBE must be at the REAR of the boiler.

Step 34 Install burner bolts 1. Press the burner flange down firmly and install bolts, washers and nuts supplied. 2. Place bolts ONLY at the bolt notches marked in Step 32, page 13. 3. Secure the bolts firmly, but avoid distorting the burner flange.

Step 35 Position the manifold 1. Place the manifold on top of the section assembly as shown, with the blower flange to the FRONT of the boiler.

Step 36 Install manifold bolts 1. The manifold gasket is pre-attached to the manifold at the factory. 2. Install a bolt, two flat washers, split lock washer and nut at each bolt lug on the manifold. 3. Tighten the bolts only until the split lock washer is just flattened.

14

P/N 42-9551

KN Series Gas-fired direct vent cast iron boilers – Field assembly instructions

Step 37 Install pilot assembly 1. Use a flashlight to look down through the pilot mounting hole at the top rear of the manifold.

4. After ensuring the pilot tube is aligned properly, insert the pilot orifice assembly as shown.

2. The pilot tube (shown in Step 34, page 14 at the top rear of the burner) must be aligned with the hole in the manifold.

5. Screw the pilot orifice into the manifold hole securely. DO NOT overtighten.

3. If the pilot tube is not aligned, use a screwdriver to reach into the manifold hole and coax the pilot tube into position.

Step 38 Install burner inspection port

1. The burner inspection port consists of a plate, gasket, inspection glass, and another gasket. 2. Place against the mounting boss on the top front section. 3. Secure with the bolts and washers provided.

Step 39 Install plug in front section lower nipple port tapping

1. Obtain the 3” flat plug supplied with the boiler. 2. Apply pipe dope to the tapping and the plug. 3. Install the plug securely.

P/N 42-9551

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KN Series Gas-fired direct vent cast iron boilers – Field assembly instructions

Step 40 Apply jacket front insulation Leather gloves are recommended when handling sheet metal components. They will reduce the possibility of cuts from sheet metal edges.

1. Press jacket front insulation against the back of the front panel.

Step 41 Mounting hole alignment 1. The installer is pointing to the jacket panel mounting hole toward the left center of the jacket front panel. 2. Insert a screwdriver through this hole and the insulation to help align the hole to the mounting boss on the front section while placing the jacket front panel. 3. Position the jacket front panel on the section and secure with a bolt through this hole.

Step 42 Install gas line bracket 1. Install the gas line bracket to the right front using the bolts provided.

16

P/N 42-9551

KN Series Gas-fired direct vent cast iron boilers – Field assembly instructions

Step 43 Apply jacket rear insulation Use of an approved dust respirator is strongly recommended when handling the insulating components of the boiler.

1. Press jacket rear insulation against the back of the rear panel.

Step 44 Install jacket rear panel The jacket rear panel is supplied with the igniter and conduit box installed. Leather gloves are recommended when handling sheet metal components. They will reduce the possibility of cuts from sheet metal edges.

1. Insert a screwdriver through the left center jacket mounting hole. 2. Use the screwdriver to help align the mounting hole with the mounting boss on the rear section. 3. Secure the jacket rear with the bolts provided. 4. Apply the upper left bolt and the two lower bolts. 5. The fourth jacket mounting hole is under the conduit box. Temporarily remove this box to install the bolt. Then re-install the box.

P/N 42-9551

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KN Series Gas-fired direct vent cast iron boilers – Field assembly instructions

Step 45 Install flue adapter Make sure the flue adapter condensate nipple is located at the BOTTOM when installed. Rubber gloves are recommended for this procedure.

1. Apply silicone RTV to the flue adapter mounting boss. 2. Position the flue adapter on the boss and insert the four mounting bolts. The condensate nipple must be pointed DOWN.

Step 46 Install supply nipple The boiler is supplied with two nipples that include three control tappings. The nipples are identical, but they must be positioned differently.

1. Apply pipe dope to one of the 3-inch nipples and the upper right tapping on the rear of the boiler. 2. Install the supply nipple in the tapping. 3. When the nipple is tightened, it must be in the orientation shown — the ½” tapping must be on top, with a ¾” tapping at the right and at the bottom. 4. The ½” tapping is used for the 10K supply sensor.

Step 47 Install supply nipple The boiler is supplied with two nipples that include three control tappings. The nipples are identical, but they must be positioned differently.

1. Apply pipe dope to one of the other 3-inch nipple and the lower left tapping on the rear of the boiler. 2. Install the return nipple in the tapping. 3. When the nipple is tightened, it must be in the orientation shown — the ½” tapping must be on right, with a ¾” tapping at the bottom and at the left side. 4. The ½” tapping is used for the 10K return sensor. 5. The ¾” bottom tapping is used for the boiler drain. 6. The ¾” side tapping should be plugged unless used for a special purpose.

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P/N 42-9551

KN Series Gas-fired direct vent cast iron boilers – Field assembly instructions

Step 48 Install the ignition electrode assembly Check/adjust the igniter electrode positioning before installing. They are not factory preset.

1. Check the distance from the ignition electrode plate to the front end of the ignition electrode ceramics. It must be 1½ inches (see dimension “A” in drawing at right. 2. Check the spacing between the igniter tips. It must be 1/8 inch (see drawing at right). 3. If the electrodes are not positioned correctly, loosen the mounting screws and adjust. 4. Apply the gasket to the back of the ignition electrode plate. 5. Bolt the plate to the boiler. 6. Attach the electrode wires to the electrodes. Then slide the rubber boots over the connections.

Step 49 Attach the UV scanner 1. Attach the UV scanner to the threaded boss on the electrode plate assembly.

Step 50 Mark the gas line nipple The gas line nipple is factoryattached to the mounting brackets. The nipple must be removed for connection to the gas train. This step ensures the nipple is correctly placed when re-attached to the bracket.

P/N 42-9551

1. Use a marker pen to mark the location of the two mounting clamps on the gas line nipple. 2. Mark the gas line nipple to indicate which end is the top.

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KN Series Gas-fired direct vent cast iron boilers – Field assembly instructions

Step 51 Mount the control panel The control panel mounts on the mounting clip at the top of the jacket front panel. The conduit fitting and the sensor hose must be routed through jacket panel.

1. BX conduit fitting — Hold the control panel close enough to the jacket front panel to allow inserting the conduit fitting through the back of the panel. Then apply and tighten the fitting lock nut. 2. Feed the sensor hose through the grommet-fitted hole in the jacket panel (see second photo). 3. Then clip the control panel to the mounting bracket.

Step 52 Attach the gas line nipple to the gas train

1. Apply pipe dope to the gas line nipple bottom end. REMOVE any pipe dope from the inside of the pipe.

Step 53 Tighten gas line nipple Use two wrenches to prevent damage to gas train components.

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1. Use two pipe wrenches to tighten the gas line nipple connection.

P/N 42-9551

KN Series Gas-fired direct vent cast iron boilers – Field assembly instructions

Step 54 Mount the gas train 1. Attach the gas train to the front of the boiler using the bolts supplied.

Step 55 Re-attach gas line nipple brackets

1. Re-attach the gas line nipple mounting brackets, but leave loose. The gas line will have to be manipulated in a following step. 2. Loosen the U-clamp on the gas train to allow the gas train to be rotated as the gas line nipple is pulled forward in a later step.

Step 56 Apply blower flange gasket

1. Remove the protective backing from the blower flange gasket to expose the adhesive. 2. Place carefully on the blower flange and press in place.

Step 57 Install gas line grommet in air box

P/N 42-9551

1. Install the gas line grommet provided into the gas line opening on the bottom of the air box.

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KN Series Gas-fired direct vent cast iron boilers – Field assembly instructions

Step 58 Move the air box/blower assembly into position

1. This procedure requires two people. 2. Move the air box/blower assembly into position. 3. Guide the gas line into the grommetfitteded opening in the bottom of the air box.

Step 59 Attach the air box/blower assembly to the manifold blower flange

Step 60 Tighten gas line nipple clamps and gas train clamp

1. Use the nuts provided to secure the assembly to the manifold blower flange.

1. Securely tighten the gas line nipple clamps. 2. Tighten the gas train U-clamp.

Step 61 Connect air box pressure switch sensing tube

1. Remove the air pressure sensing tube from the air box. 2. The air box pressure switch is mounted on the lower center of the jacket front panel. 3. Connect the tube to the air pressure switch and to the hose barb on the bottom of the air box.

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P/N 42-9551

KN Series Gas-fired direct vent cast iron boilers – Field assembly instructions

Step 62 Install gas valve by-pass line De-burr the aluminum tubing after cutting to ensure the ends are not obstructed.

1. Connect an aluminum tube (supplied with boiler, but cut to length during installation) from the gas valve by-pass outlet port to the gas valve by-pass inlet port (rear of valve).

Step 63 Connect gas valve air box sensor line De-burr the aluminum tubing after cutting to ensure the ends are not obstructed.

1. Connect an aluminum tube to the bottom of the gas valve (PL-AIR tapping). 2. Connect the other end of the tubing to the brass fitting on the bottom of the air box.

Step 64 Connect pilot gas line De-burr the aluminum tubing after cutting to ensure the ends are not obstructed.

1. The pilot gas line aluminum tube must connect from the pilot gas valve on the front of the boiler to the pilot orifice assembly on the top of the manifold (top rear). 2. Cut the tube with extra slack to ensure it will be long enough after the jacket side panel is installed. 3. Route the tubing through the hole in the front jacket panel. 4. Connect the tubing to the pilot gas valve (at front of boiler). 5. Leave the other end of the tube loose.

Step 65 Apply right side jacket insulation Use of an approved dust respirator is strongly recommended when handling the insulating components of the boiler.

P/N 42-9551

1. Press the right side insulation into place. 2. Make sure to position the insulation UNDER the pilot gas line tubing. 3. Cut the pilot gas tubing if necessary, then attach to the pilot orifice assembly at the top rear of the manifold.

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KN Series Gas-fired direct vent cast iron boilers – Field assembly instructions

Step 66 Install jacket right side panel Leather gloves are recommended when handling sheet metal components. They will reduce the possibility of cuts from sheet metal edges.

1. Secure the jacket right side panel in place using the screws provided. 2. Position the pilot gas tubing in the slot located in the top right end of the jacket right side panel.

Step 67 Install jacket top left panel Leather gloves are recommended when handling sheet metal components. They will reduce the possibility of cuts from sheet metal edges.

1. Mount the jacket top left panel to the boiler using the screws provided. 2. The openings in this panel are used to install controls in the boiler top left tappings.

Step 68 Mount controls in top left tappings

1. There are 11 tappings in the top left — 1¼-inch tappings at the front and rear of the boiler — the (9) tappings in between are all 1 inch. 2. Rear tapping — install the boiler relief valve. 3. Second tapping from the rear — mount the manual reset limit control. 4. Third tapping from the rear — mount the automatic air vent. 5. Sixth tapping from rear — mount the remote low water cutoff probe and J-box. 6. Front tapping — mount the pressure/ temperature gauge. 7. All other tappings — install 1-inch plugs.

Step 69 Install left side junction box

1. Connect the three BX conduits (from the front, top and rear of the boiler) to the left side junction box, provided. 2. The wires are both color-coded and numbered. 3. Connect the wires together, matching color/number. 4. Install the junction box cover.

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KN Series Gas-fired direct vent cast iron boilers – Field assembly instructions

Step 70 Route plastic sense line through jacket rear

1. Disconnect the rear conduit junction box before proceeding. 2. Guide the plastic sense line through the grommeted hole in the jacket rear panel. 3. Re-attach the rear conduit junction box.

Step 71 Apply left side jacket insulation Use of an approved dust respirator is strongly recommended when handling the insulating components of the boiler.

1. Press the left side insulation into place. 2. Make sure to position the insulation UNDER the conduits and the plastic sense line.

Step 72 Install jacket left side panel Leather gloves are recommended when handling sheet metal components. They will reduce the possibility of cuts from sheet metal edges.

1. Install and secure the jacket left side panel using the screws provided.

Step 73 Install top jacket panel strips Leather gloves are recommended when handling sheet metal components. They will reduce the possibility of cuts from sheet metal edges.

P/N 42-9551

1. Install a jacket top panel strip on each side of the jacket top.

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KN Series Gas-fired direct vent cast iron boilers – Field assembly instructions

Step 74 Connect wires to air box components See the wiring diagrams, Figure 1, page 28 and Figure 2, page 30 for detailed information.

Step 75 Connect wires to air box components See the wiring diagrams, Figure 1, page 28 and Figure 2, page 30 for detailed information.

1. Connect the wires from the air pressure switch and relief valve switch to the control panel. 2. See callout 3 in schematic wiring diagram, Figure 1, page 28.

1. Connect wires from remote LWCO, gas valve molex, LGPS and pilot gas valve. 2. See callouts 1, 2, 4, 5 and 6 in schematic wiring diagram, Figure 1, page 28.

Step 76 Connect motor wires See the wiring diagrams, Figure 1, page 28 and Figure 2, page 30 for detailed information.

1. Attach the BX conduit fitting on the motor conduit to the top of the control panel. 2. Connect the wires to the matching color coded/numbered wires in the control panel. 3. See callout 7 in schematic wiring diagram, Figure 1, page 28.

Step 77 Install the air filter 1. Place the air filter in the air box as shown. 2. The left top edge of the filter must go against the inside left of the air box. 3. The bottom right of the filter goes against the bottom right of the air box.

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KN Series Gas-fired direct vent cast iron boilers – Field assembly instructions

Step 78 Install the air box cover The air box cover MUST be in place during boiler operation.

1. Attach the air box cover using the screws provided.

Step 79 Install the air gas train shroud

1. Attach the gas train shroud to the jacket front using the hardware provided.

Step 80 Follow Boiler Installation and Operating Instructions manual and HeatNet Control manual 1. Follow all instructions in both of the manuals listed. Pipe and wire the boiler accordingly. 2. Perform the tests indicated in the manuals.

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KN Series Gas-fired direct vent cast iron boilers – Field assembly instructions Figure 1

Schematic wiring diagram (numbered bullets show locations of wiring field connections (all wires color coded and numbered)

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1

2

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KN Series Gas-fired direct vent cast iron boilers – Field assembly instructions Figure 1

(Continued)

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3

4

5

6

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KN Series Gas-fired direct vent cast iron boilers – Field assembly instructions Figure 2

30

Ladder wiring diagram

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KN Series Gas-fired direct vent cast iron boilers – Field assembly instructions Figure 2

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(Continued)

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KN Series Gas-fired direct vent cast iron boilers – Field assembly instructions

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P/N 42-9551