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ATH HeatNet KN-2 Installation And Operation Instructions Manual Download Page 42

Page 42 

KN INSTALLATION AND OPERATION INSTRUCTIONS

Maintenance

13

Handling ceramic fiber 
and fiberglass materials

 

The 

K N

 boiler contains some ceramic 

fiber and fiberglass materials. Ceramic 
fiber materials, such as the burner 
gasket, may contain carcinogenic 
particles (chrystobalites) after exposure 
to heat. Airborne particles from fiberglass 
or ceramic fiber components have been 
listed as potentially carcinogenic by the 
State of California. Take the following 
precautions when removing, replacing 
and handling these items.

Protective measures

•  Avoid breathing dust and avoid contact with 

skin or eyes. Wear long-sleeved, loose-fitting 

clothing, gloves and eye protection. Use a NIOSH 

N95 certified respirator. This respirator meets 

requirements for protection from chrystobalites. 

The actual job requirements or NIOSH regulations 

may require other or additional protection. 

For information, refer to the NIOSH website, 

http://www.cdc.gov/niosh/homepage.html.

Ceramic fiber removal

•  Ceramic fiber removal: To prevent airborne dust, 

thoroughly wet ceramic fiber with water before 

handling. Place ceramic fiber materials in a plastic 

bag and seal to dispose.

•  Avoid blowing, tearing, sawing or spraying fiber-

glass or ceramic fiber materials. If such operations 

are necessary, wear extra protection to prevent 

breathing dust.

•  Wash work clothes separately from other laundry. 

Rinse clothes washer thoroughly afterwards to pre-

vent contamination of other clothing.

NIOSH First aid procedures:

•  Eye exposure — irrigate immediately

•  Breathing — fresh air.

Read before proceeding

 

Failure to adhere to the following 

could result in severe personal 

injury, death or substantial property 

damage.

Licensed technician only

The procedures in this manual must only be done by 

a qualified service technician. Some details of service 

procedures are left to the expected good practices of a 

qualified technician.

Electrical shock hazard

Except when the boiler must be tested or adjusted with 

the power on, always turn power 

OFF

 before sevicing 

the boiler.

Burn or scald risk

Always allow the boiler and parts to cool before at-

tempting to service or remove. Some parts may be very 

hot.
Do not open water piping components unless the 

water has been allowed to cool to avoid scald hazard 

from spraying hot water.

Test/verify the boiler after servicing

Following service of any kind, verify that the boiler, 

controls and system devices are fully functional by 

performing the appropriate start-up testing procedures 

given in this manual.

Seals

If any pressure-tight seal is broken for servicing (such 

as combustion chamber/burner seals, air or vent piping 

joints or seals, or gas piping joints or seals, make sure 

the seal is restored when servicing is complete. Gaskets 

must be in good position and placed as originally 

installed.

Read the instructions

Do not attempt the procedures in this manual without 

thoroughly reading the instructions given. Follow all 

instructions.

If problems can’t be resolved

If following the procedures in the 

K N

 manuals do  

not resolve problems, contact Advanced Thermal 

Hydronics for technical support to resolve the issues.

Summary of Contents for HeatNet KN-2

Page 1: ...substantial property damage The boiler can only be operated with a dust freeairsupply Followtheinstructionmanualprocedurestoductairtotheboilerairintake Iftheboilerhasbeencontaminatedbyoperation with contaminated air follow the instruction manual guidelines to clean repair or replace the boiler if necessary Affix these instructions near to the boiler water heater Instruct the building owner to reta...

Page 2: ... rectification sensing Because of its low excess air operation and controlled combustion the burner also provides low NOX emissions and quiet operation Gas valve blower and venturi Most gas valves regulate at a positive pressure downstream of the valve typically 3 inches water column ButtheKN gasvalveregulatestoZEROpressuredownstream Thisiscalleda zerogovernor valve The advantage is that gas will ...

Page 3: ...Water return connection 13 Air inlet sleeve 14 Relief valve 15 Relief valve piping by installer 16 Water supply connection 17 Fenwal ignition module 18 Ignition electrodes flame rod assembly 19 Control transformer 120 24 VAC 20 Postpurge circulator fac tory installed and piped 21 Vent connection sleeve with flue gas sampling port 22 Condensate tubing connec tion 23 Upper section cover and premix b...

Page 4: ...ervice fill out the Start up service history information on the back page Contents Customer service and technical support Please direct all questions to your distributor or contact the Advanced Thermal Hydronics Customer Service Department at 260 North Elm Street Westfield MA 01085 Phone 413 564 5515 Always include the model and serial numbers from the rating plate of the boiler in question Claims...

Page 5: ... prescribed in this manual the O2 levels must be between 5 and 7 Throughout all firing rate conditions the burner surface must never show red areas Follow manual procedures to correct this condition Boiler water Youmustthoroughlyflushthesystem withtheboilerisolatedfromthesystem toremove sediment Existing systems in particular often contain large amounts of iron sediment Excess suspended solids in ...

Page 6: ...irements Voltage 120 vac 60 hz 1 phase Current draw 120 volt power line Amperes 2 5 5 Thermostat anticipator setting Amperes 0 5 Operating control HeatNet control 4 Control operation options Stand alone HeatNet BMS boiler management system 4 Control methods Heat demand HeatNet or stand alone On Off BMS 4 20 ma input Staging RS485 digital communication 4 Notes 1 2 3 4 5 DOE Heating capacity is base...

Page 7: ...e intake air option isn t used Any building utilizing other gas burning appliances a fireplace wood stove or any type of exhaust fan must be checked for adequate combustion air when all of these devices are in operation at one time Sizing of an outside air duct must be done to meet the requirements of all such devices The boiler must be supplied with combustion air in accordance with Section 9 3 A...

Page 8: ...um SERVICE OPERATION clearances given in Table 2 Failure to provide adequate ventilation could result in overheating of the boiler components or the room potentially causing severe personal injury death or substantial property damage Clearances for service and operation Theinstallationmustprovidereasonableaccessandclearanceforservice and operation of the boiler Table 2 gives recommended minimum cl...

Page 9: ...ngs exposed to the outside atmosphere have a continuous water vapor retarder with a rating of 1 perm or less with openings gasketed Weather stripping has been added on openable windows and doors Caulking or sealants are applied to areas such as joints around windows and door frames between sole plates and floors between wall ceiling joints between wall panels at penetrations for plumbing electrica...

Page 10: ... injury death or substantial property damage Connecting the relief valve Connect 3 4 inch NPT black iron pipe and fitting so the relief valve as shown in Figure 4 Follow all instructions provided in the relief valve manufacturer s instructions and labeling Neverinstallanytypeofvalvebetweentheboiler and the relief valve or in the relief discharge piping An explosion could occur causing severe perso...

Page 11: ...ch Additional high limit controls For ASME CSD 1 or Canadian applications or when required by applicable codes install an additional high limit control in the supply piping above the boiler Makesurethelimitcontrolissetatleast20 Fabovethehighestoperatingtemperature of the KNboiler Boiler piping connections TheboilersupplyandreturnconnectionsareshowninFigure 4 Both connections are 1 1 4 inch NPT Siz...

Page 12: ...above the water in direct contact with the water See Figure 5 right side See Figure 7 for suggested piping Guidelines for closed type expansion tanks NEVER use automatic air vents in systems with closed type tanks The air must be kept in the system and returned to the tank in order to keep the tank operating correctly Automatic air vents will bleed air out of the system resulting in water logging ...

Page 13: ...Zone circulator 15 Differential pressure by pass valve Use when high head circulator may cause noise erosion or valve lifting problems when only a few zone valves are open 16 Boiler postpurge circulator see page 11 KN 2 only 17 Header sensor required where shown Isolation valve Purge valve Suggested locations allow for improved system filling and draining and initial air elimination Temperature ga...

Page 14: ...ow checkvalvesasshown Thesepreventforced flow in idle zones Legend 1 KNboiler 2 Boiler circulator 4 Boiler system circulator 5 Indirect fired DHW tank when used 6 DHW circulator 7 Flow check valve 8 Cold water fill line 9 Expansion tank shown with diaphragm type see page 12 for piping a closed type tank Expansion tank shown with diaphragm type see page 12 for piping a closed type tank 10 Air separ...

Page 15: ...low checkvalvesasshown Thesepreventforced flow in idle zones Legend 1 KNboiler 2 Boiler circulator 3 System circulator 5 Indirect fired DHW tank when used 6 DHW circulator 7 Flow check valve 8 Cold water fill line 9 Expansion tank shown with diaphragm type see page 12 for piping a closed type tank Expansion tank shown with diaphragm type see page 12 for piping a closed type tank 10 Air separator w...

Page 16: ...rs are piped in parallel as in Figure 12 connect the DHW tank as a zone off of the main header or install boilers dedicated to the DHW application Legend 1 KNboiler 4 Boiler system circulator 5 Indirect fired DHW tank when used 6 DHW circulator 8 Cold water fill line 9 Expansion tank shown with diaphragm type see page 12 for piping a closed type tank Expansion tank shown with diaphragm type see pa...

Page 17: ... system circulator ensure that the flow never drops below the total minimum for all boilers connected The boiler loop can be any of the designs in this manual or per standard engineering practices Use the balancing valve to adjust the boiler loop flow Expansion tank air control Chilled water systems generally use closed type expansion tanks DO NOT use automatic air vents in these systems All air m...

Page 18: ...the gas type The KN comes from the factory ready to be piped to the gas supply If for any reason the boiler is not for the type of gas available at the installation site call your representative to resolve the problem See WARNING below Gas supply components Figure14depictstheproperwaytoconnecttheboilertothegas supplypiping Thegasconnectionattheboileris1 2inchNPT Item1 Installthegaslinepipingfromth...

Page 19: ...re naturalgasorpropane bothfor flowing and static conditions 2 inches 102 mm water column Maximum gas supply pressure natural gas or propane both for flowing and static conditions 14 inches 356 mm water column Sizing guidelines The sizing recommendations of Table 3 are taken from the National Fuel Gas Code ANSI Z223 1 NFPA 54 Propane values are based on adjustment from propane specific gravity and...

Page 20: ...o 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 ratedshut offswitchshouldbelocatedat the boiler The boiler must be grounded in accordanc...

Page 21: ...tion Itmust be used as supplied from the factory It circulates water after the boiler stops firing to prevent potential damage from heat pocketing in the top of the heat exchanger Thepostpurgecirculatorisfactory pipedandpre wired Do not change the usage the wiring the location or the piping Boiler circulator See section 5 of this manual for circulator piping Figure19 shows wiring of the Boiler cir...

Page 22: ...e controller For other applications such as circulator relays or zone controllers see Appendix A in this manual Also see the Control manual Polarity The connections to the IAR positive terminals IAR must be to the same location on the zone valve as the thermostat wire as shown in Figure A1 The connections to the IAR negative terminals IAR must be from the zone valve terminal connected to the 24VAC...

Page 23: ...ts Connect thermostat zone valve end switches or remote start relay contact here Test when done to ensure no stray voltage is present on any of the wires See the Boiler manual for procedure Master boiler Connect override contacts only Individual boilers if piped appropriately can be activated for override operation such as DHW heating or emergency space heating The boiler is shipped with a jumper ...

Page 24: ... OPERATION INSTRUCTIONS KN 2 only Figure 21b KNwiring summary see Figure 21 for locations see Boiler manual and Control manual text for additional information Wiring and control setup continued 7 Also see page 21 Also see page 22 ...

Page 25: ...at least twice and the display will show the first STANDBY display in Figure 22 Note that pushing the DOWN button on the keypad will change the right side of the display as shown providing information on various setpoints and parameters 5 The display LOC SET means the setpoint temperature Figure 22 shows the factory default values Accessing setup menus 1 With the display in STANDBY press and hold ...

Page 26: ...t never be higher than the OP LIMIT setting minus the LIMIT BAND minus half of the HEAT BAND setting This would cause the boiler to hit limit while trying to modulate Example If LIMIT BAND is 20 F OP LIMIT is 215 F and HEAT BAND is 30 F the local setpoint must never be higher than 215 20 30 2 180 F Set the DHW setpoint DHW SETPT 1 Skip this procedure if the boiler is not used for DHW heating 2 Use...

Page 27: ...e cursor points at OA RESET 2 The default setting is ON 3 To change the setting press SELECT and use the arrow keys to change from ON to OFF 4 Press SELECT then BACK 5 If outdoor reset is enabled set the reset temperatures as follows 6 Use the arrow keys until the cursor points at SET OA SETPTS 7 Press SELECT and the display will show 8 Don t use the arrow keys yet but if you use the DOWN arrow tw...

Page 28: ... fans fireplace dampers and any other gas burning appliance to their previous condition of use 7 Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code ANSI Z223 1 NFPA 54 When resizing any portion of the common venting system the common venting system should be resized to approach the minimumsizeasdeterminedusingtheappr...

Page 29: ...ic poses a risk to the tubing install a cover over the tubing or some other means to protect it from damage or movement Prevent freezing Do not route the line through or terminate the line in any area that could expose the condensate to freezing temperatures Floor drain termination If the condensate line can be routed to a floor drain and applicablecodesdonotprohibitdraininguntreatedcondensate ter...

Page 30: ...r use in hydronic systems Replacement boiler installations often have large amounts of accumulated sediment and corrosion that must be removed to ensure boiler life and reliable operation Flush each zone of multi zone systems individually using the purge valves and isolation valves in the system Flush until the water runs clean After flushing the system thoroughly use trisodium phosphate orotherch...

Page 31: ...aturethatthesystemandboiler temperature controls will allow The pressure in the boiler must never be below 12 psig Lower pressure could allow localized boiling in the boiler heat exchanger causing possible damage and section failure At cold fill the water level in closed type expansion tanks should not be above center Use the tank fitting to verify tank water level is correct As the system heats u...

Page 32: ...erwards have the propane supplier check verify the odorant level Never attempt to measure gas valve outlet pressure Do not attempt to measure the boiler gas valve outlet pressure The high negative pressure in the venturi can suck fluid out of a manometer pulling it into the gas valve This would destroy the gas valve rendering it unusable Start up checklist Read all boiler manuals The KNis supplied...

Page 33: ...ain manual gas valve and check the gas piping and joints in the boiler Check for leaks if not already done following the instructions on page 19 Starting the boiler continued Prepare the condensate system Verify the condensate line is connected to the boiler cor rectly installed and terminated Turn on power to the condensate pump if used Make sure the condensate neutralization system if used is fu...

Page 34: ...RE PURGE Ignition trial ON at ignition RPM 30 of maximum 4 seconds ON ON IGN 30 Flame is sensed Stabilization period ON at ignition RPM 30 of maximum 6 seconds OFF ON IGN 30 Operate on demand ON at RPM based on demand control determines firing rate based on demand and rate of change etc Demand OFF ON RUN XXX End call for heat ON at purge RPM 55 of maximum OFF OFF POST PRGE Ignition failure ON at p...

Page 35: ...ll for gas including near the floor If you smell gas Follow B in the safety information above If you don t smell gas go to the next step 6 Turn manual gas valve handle counterclockwise to the gas valve 7 Turn ON all electrical power to the boiler 8 Set the thermostat to its highest setting Press the ON OFF switch to 9 The DISPLAY will cycle through the ignition sequence and show RUN when the boile...

Page 36: ...Page 36 KN INSTALLATION AND OPERATION INSTRUCTIONS Illustration 26 En francaise Starting the boiler continued 12 ...

Page 37: ...tected skin could result in a severe burns 2 Slide the hose clamp off of the sample opening 3 Insert the combustion analyzer probe into the sample opening 4 If using an electronic analyzer zero and calibrate it before proceeding 5 Ifusingachemicalanalyzer makesurethatthefluidisfreshandisatroomtemperature Have a monoxer and test tubes available to test carbon monoxide levels Check high fire operati...

Page 38: ...ual gas valve Gas pressure should never fall off by more than 2 inches WC 50 mm To meter gas input natural gas only 1 Meter gas input with the high fire jumper in place 2 Turn off all other gas appliances that use the same gas meter as the boiler 3 Call your gas supplier and ask for the heating value of the gas Btu per cubic foot 4 Start the boiler and let it run for 15 minutes high fire jumper in...

Page 39: ...e seven Phillips head screws securing the jacket top to the jacket sides 10 Lift off the jacket top Leave the wire harnesses connected 11 Move the insulation aside if necessary Adjusting the low fire setting DO NOT adjustthelow firesettingunlesslow fireflameorcombustion are unacceptable 1 See Figure 31 for the location of the gas valve low fire adjustment Use a 2 mm hex wrench 2 When adjusting the...

Page 40: ...en continue through a normal start cycle 4 With the manual gas valve closed the boiler should attempt ignition three times then lockout as described below Ignition failure 1 Make sure there is a call for heat 2 Turn the boiler on off switch OFF 3 Close the manual gas valve on the gas supply line 4 Turn the boiler on off switch ON 5 The boiler should start a regular cycle 6 When the boiler attempts...

Page 41: ...actory for corrective action Operating the boiler with a damaged or 13 obstructed heat exchanger could result in severe personal injury death or substantial property damage Verify boiler water treatment If the system requires water treatment make sure the treat ment is being performed as required Ensure that the water softener if used is operational and is being maintained If the system uses antif...

Page 42: ... First aid procedures Eye exposure irrigate immediately Breathing fresh air Read before proceeding Failure to adhere to the following could result in severe personal injury death or substantial property damage Licensed technician only The procedures in this manual must only be done by a qualified service technician Some details of service procedures are left to the expected good practices of a qua...

Page 43: ...thumbscrews and finger tighten securely 11 Turn the boiler on off switch ON Accessing the electrode assembly 1 Turn the boiler on off switch OFF 2 If the boiler ignition electrodes or flame rod appear to be operating incorrectly remove and inspect the assembly as follows Do not remove the electrode assembly while the boilerisoperating Allowtheboilerandelectrode assembly to cool before attempting r...

Page 44: ...Disconnect the three wire harnesses at the gas valve and blower items 2 and 3 Figure 36 In this illustration the wires are not shown 9 Lift the upper cover plate blower gas valve assembly off of the section assembly The upper section cover gasket is adhered to the bottom the cover with silicone RTV 10 The burner is now exposed 11 Lift the burner up as in Figure 37 and inspect both sides The burner...

Page 45: ...Page 45 KN INSTALLATION AND OPERATION INSTRUCTIONS Maintenance continued 14 Notes ...

Page 46: ... 39 02 3927 Operator Supply Sensor 1 40 03 1776 Ignition Box Cover 1 41 09 1520 TACO 005 W Internal Flow Check 1 ITEM PARTNo DESCRIPTION QTY 42 56 3346 3 Flue Adapter 1 45 26 3211 50V Transformer 1 46 02 4288 Breakout Board w Wire Connectors 1 NS 02 4279 RS485 Communication Board 1 NS 02 4350 Protocarrier 1 NS 70 1427 5K Resistor Assembly 1 NS 58 1831 5K Resistor 1 NS 70 2074 Harness J2 Ctrl 1 NS ...

Page 47: ...Page 47 KN INSTALLATION AND OPERATION INSTRUCTIONS KN 2 Replacement parts continued 15 ...

Page 48: ...Page 48 KN INSTALLATION AND OPERATION INSTRUCTIONS KN 4 Replacement parts 15 3 1 4 5 7 6 8 3 9 12 10 11 13 22 24 25 34 35 38 37 36 2 26 31 23 33 32 30 29 28 27 75 76 14 15 16 17 18 19 20 21 ...

Page 49: ...9 KN INSTALLATION AND OPERATION INSTRUCTIONS KN 4 Replacement parts continued 15 47 46 45 44 43 42 41 40 39 9 49 50 51 52 53 48 55 54 59 56 58 57 72 71 68 69 58 67 22 64 61 60 22 31 65 63 62 66 31 70 26 73 74 ...

Page 50: ...ief Valve 1 38 22 1803 75 psi Relief Valve 1 38 22 1201 100 psi Relief Valve 1 39 45 1272 Ceramic Chamber 1 40 59 1096 Lower Chamber Gasket 1 41 70 1681 Burner Assembly 1 ITEM PARTNo DESCRIPTION QTY 70 1209 Burner Only 1 43 58 1837 Blower 1 NS 40 00268 Wire Harness Blower to Inline 1 NS 06 00020 Blower to Swirlplate Gasket 1 44 01 1651 Inlet Adapter Casting 1 45 02 1590 Intake Adapter 1 46 02 1589...

Page 51: ...transformer to be shorted out and damaged 3 wirezonevalves Youwillhavetorewireexisting3 wirezonevalves tomeettherequirementsshowninFigure A1 Movethethermostatlead and the 24VAC hot lead to the CENTER terminal of the valve Move the 24VAC common lead to the outer terminal of the valve Discard existing wires connected to the end switch terminals Install a new wire single wire from each end switch to ...

Page 52: ...r or install relays that provide a 24VAC common terminal Heat Demand terminal connections using circulator relays The end switch leadsfromtherelaysmustconnecttotheHeatDemandterminalsontheelectrical connection board as shown in Figure A2 IARconnections SeeFigure A1fortypicalwiringtotheIARinputswhenusing circulator relays For other applications see the Control manual and Section 7 of this manual Pol...

Page 53: ...e IAR negative terminals IAR must be from the zone controller s 24VAC common terminal as shown Connecting the wires incorrectly can cause the transformer to be shorted out and damaged Thermostat terminal connections Use a voltmeter to verify the wiring is correct Measure the voltage on the thermostat terminals with the zone controller powered BEFORE connecting any wires The IAR positive terminal c...

Page 54: ...CTIONS 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 Appendix A suggested wiring continued 16 ...

Page 55: ...nd opened as needed Limits and interlocks tested Water piping correct and operational Metered gas input natural gas Gas supply pressure tested verified DHW system tested if applicable Gas supply piping correct Explained User s manual to owner Flame observed and combustion tested Instruction manual will be kept at site Service history complete before leaving boiler site after service Service date T...

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 905 670 5888 FAX 905 670 5782 www knseries com ...

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