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ATH KN-10, Assembly Instructions Manual

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ATH KN-10 Assembly Instructions Manual Download Page 23

23

Gas-Fired Direct Vent Cast Iron Boilers – Field Assembly Instructions

Figure 2 

Boiler materials

Skid 1

Sections (front, back and intermediate)

Long bolts for temporary attachment of front and rear 
sections to base

Skid 2

Skid with base, push nipples, draw rods, pipe plugs 
(from BFC)

Oak timbers

RTV/Prodope/plug driver kit

Drain pan assembly

Upper cover assembly

Burner & distribution plate weldment

Burner mounting plate

Combustion chamber — segmented, assembly of

Gasket - burner to ceramic fi ber chamber

Jacket panel - left side upper

Jacket panel - left side lower

Jacket panel assembly — right side

Jacket panel — right side

Jacket panel — top right cover

Jacket panel — top left cover

Crate 1

Hardware box kit assembly

Drain pan hardware kit

Upper cover/burner assembly hardware kit

Rear jacket panel mounting hardware kit

Front jacket panel mounting hardware kit

Supply/return nipple pipe fi tting kit

Flue transition casting hardware kit

Filter box assembly mounting hardware kit

Jacket assembly hardware kit

Control panel mounting hardware kit

Return & supply nipple weldment  KN-26 & 30

Supply nipple sensor kit

Supply nipple fl ow switch kit

Return nipple sensor kit

Flue transition assembly kit

Crate 1

Filter box assembly kit

Pilot assembly kit

View ports assembly kit

Rear jacket panel assembly kit

Front jacket panel assembly kit

Bracket - fi lter box support 

Jacket panel assembly — control enclosure right side

Jacket panel assembly — control enclosure left side

Control panel assembly kit

Gas train assembly kit

Low water cut off  assembly kit

Hi limit assembly kit

Manual reset hi limit assembly kit

Air vent assembly kit

Hidden panel assembly

Wire harness/Molex — J4/J1 to blower Hnet 3.0  

Aluminum tubing — 1/4" x 42" (gas valve to right control 
panel) 

Aluminum tubing — 1/4" x 39" (pilot train to right control 
panel) 

Aluminum tubing — 1/4" x 11" (right control panel to fi lter 
box) 

Aluminum tubing — 1/4" x 39" (right control panel to 
pilot) 

Condensate drain assembly kit

Jacket panel insulation — rear 

Jacket panel insulation — front

Jacket panel insulation — left

Jacket panel insulation — right

Ignitor assembly kit

Control enclosure top panel assembly kit

Jacket panel assembly — control enclosure front

Gas train shroud assembly

Filter bag

Summary of Contents for KN-10

Page 1: ... 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 retain the inst...

Page 2: ...tions to your distributor or contact the Advanced Thermal Hydronics 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 Code compliances All aspects of...

Page 3: ...ure leading to possible severe personal injury death or substantial property damage COMPONENTS AND SPECIAL TOOLS REQUIRED Recommended Assembly Crew The assembly crew should be a minimum of 3 experienced technicians Equipment Materials Required For Assembly 1 One quart 30 wt motor oil 2 Flexible leather work gloves 3 Dead blow hammer with plastic face DO NOT use a sledge hammer 4 Four 2 x 4 x 12 bo...

Page 4: ...ced as the front end 3 Place a beam supplied against each side as a runner as shown at right 4 The planed surface of the beam must be on top 5 If beam has any curvature place the beam with the curvature toward the OUTSIDE of the frame 6 Space runner beams with about even lengths extending off of each end of the base 7 The runner beams will be used to support the boiler block during assembly then r...

Page 5: ... 1 Use a 3 8 x 6 inch bolt wedge flat washer split lock washer and nut on each side as shown 2 Point the wedge narrow edge toward the section Wedge Point thin edge toward the section 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 The bolt must be secure to prevent movement of the front sectio...

Page 6: ...ctly Step 8 Mix push nipple lubricant Work 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 Mix about 1 part of oil to 20 parts of the pipe dope 2 The consistency should be similar to thick paint and should flow easily 3 You will need enough mixture to lubricate all nipple ports and all push n...

Page 7: ...les 2 Inspect carefully and wipe off the nipples with a clean cloth 3 Brush the outside surface of each push nipple VERY LIGHTLY with the push nipple lubricant 4 Wipe off any excess lubricant Step 12 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 1 Insert ...

Page 8: ...of the two draw rods The back sides large surface of the bearing plates must face toward the sections away from the nuts The ribbed side of the bearing plate shown in the photo below must face the nut 7 8 inch nuts and washers Bearing Bearing plates plates Place bearing plate with flat side Place bearing plate with flat side away from the nut away from the nut When block assembly is completed with...

Page 9: ...7 Install remaining intermediate sections and then the rear section see previous pages for details Step 6 Apply adhesive for ceramic fiber flue baffle Step 11 Lubricate push nipples with oil pipe dope mixture see Step 8 Step 14 File lower edges of next section Step 7 Place ceramic fiber baffle in flueway Step 12 Insert push nipples Step 15 Install next section and prepare draw rods Step 9 Lubricat...

Page 10: ...alignment of the section leg slots with the hole in the legs pry section into position as needed 8 Install the 3 8 x 4 1 2 inch bolts nuts washers and wedges on all four legs as in Step 5 Step 19 Insert the tie rods then tighten tie rod nuts using a torque wrench The tie rods ARE NOT used to pull the sections together ONLY to keep them firmly in position 1 After the block has been bolted to the fo...

Page 11: ...er 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 22 Install condensate drain pan The condensate drain pan must be sealed completely around all edges to prevent flue gas leakage 1 This procedure requires two people to do correctly 2 Guide the condensate drain pan through the f...

Page 12: ...could develop resulting in severe damage Repair all leaks at once If block leaks should occur repair if possible Contact your representative for instructions if necessary 1 Apply blanking flanges and gaskets to the 4 inch flanged supply and return connections at the boiler rear 2 Apply pipe dope and pipe tape to the two 3 inch recessed plugs and install in the front section top left and lower righ...

Page 13: ... protective packaging 2 Carefully place the four combustion chamber side pieces in the top as shown 3 The combustion chamber should sit evenly in the opening with its FLAT surface facing up and even with the surface of the sections 4 Use the loose ceramic fiber wadding supplied with the boiler to pack the corners of the chamber This will hold the pieces firmly in position and ensure a tight seal a...

Page 14: ...oiler 1 Carefully align the burner flange on top of the burner 2 Apply a generous bead of silicone sealant completely around the flange about 1 inch inside the bolt notches Step 31 Install the manifold 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 handli...

Page 15: ...fore placing the jacket top panel and then installing the top mounted components 3 Place the jacket top panel over the top openings after plugging opens that won t be used 4 Top rear tappings Rear 1 Rear 1 Rear 2 Rear 2 Rear 3 Rear 3 Rear 4 Rear 4 5 Rear 1 is for relief valve Rear 2 is for the MANUAL rest high limit Rear 3 is for the air vent Rear 4 is for the low water cutoff 6 Top front tappings...

Page 16: ...d when handling the insulating components of the boiler 1 Insert and drive the jacket front studs into the stud bosses nine locations 2 Cut cross slots in the insulation at each stud location and press the insulation onto the studs Slide a steel spacer over each stud 3 Place the jacket front panel over the studs and secure with nuts and washers provided 4 They come welded to the sheet stainless st...

Page 17: ...wing connections are made Some of these connections will be made in later steps as additional components are added See the wiring diagrams supplied with the boiler for details The following is a list of connections to be made Wires are tagged with destinations 4 When boiler assembly is complete follow the boiler manual and the wiring diagrams to complete field control wiring and power connections ...

Page 18: ...between the electrode tips This dimension must be 1 8 inch 3 Apply the gasket and bolt in place using the hardware provided DO NOT overtighten Connect wires Step 41 Install the jacket left side insulation and panel Use of an approved dust respirator is strongly recommended when handling the insulating components of the boiler 1 Insert left side insulation under the top left panel 2 Tuck in the ins...

Page 19: ...et panel is applied 3 Install the jacket right side panel making sure all tabs fit into the mating grooves in front and rear jacket panels 4 Install the control enclosure side panels using screws provided Step 43 Install gas train and gas line 1 Obtain gas train and gas line 2 Bolt the gas train brackets to the four lower center studs on the boiler front using the hardware provided 3 Install the g...

Page 20: ... Step 46 Complete wiring 1 Obtain the HeatNet display panel assembly 2 Complete all wiring connections from the control panel to the display panel components 3 Mount the display panel and the control enclosure front panel 4 Complete all wiring connections and secure conduit ends 5 Install the control enclosure cover panel electrical cover panel and gas train cover panel ...

Page 21: ... view 3 Rear showing piping and components 4 Top rear components 5 Top front components 6 Manifold top Step 48 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 ...

Page 22: ...Gas Fired Direct Vent Cast Iron Boilers Field Assembly Instructions 22 Figure 1 Plastic tube routing ...

Page 23: ...trol panel mounting hardware kit Return supply nipple weldment KN 26 30 Supply nipple sensor kit Supply nipple flow switch kit Return nipple sensor kit Flue transition assembly kit Crate 1 Filter box assembly kit Pilot assembly kit View ports assembly kit Rear jacket panel assembly kit Front jacket panel assembly kit Bracket filter box support Jacket panel assembly control enclosure right side Jac...

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 ...

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