ATH KN Series Installation And Operation Instructions Manual Download

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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 these

instructions. 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.

Affix these instructions near to the boiler/water heater. Instruct the building owner to retain the instructions for future use by a qualified

service technician, and to follow all guidelines in the User’s Information Manual. Dimensions are in INCHES (IN), FEET (FT),

MILLIMETERS [mm] or METERS [m].

Cast Iron Condensing Boilers
KN-Series Plus

KN6+, KN10+, KN16+, KN20+,

KN26+, KN30+ and KN40+

Boiler Manual

Installation and Operation

Instructions

KNP-IOM2-1221

42-9555

Also read and follow:

KN Control Manual

Summary of Contents for KN Series

Page 1: ...oiler 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 instructions for future us...

Page 2: ...G PRESSURE OF 100 PSI 700 kPa WATER INSTALLER THESE INSTRUCTIONS TO BE AFFIXED ADJACENT TO THE BOILER WATER HEATER CONSUMER RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE PURPOSES CONTENTS Before Your Start page 2 Ratings Capacities page 3 Location page 3 Combustion Air Ventilation page 3 Venting Guidelines page 5 Common Vent Systems page 15 Outdoor Venting page 19 General Piping Requirements page...

Page 3: ... flooring but never on carpeting 4 Locate the boiler in an area that will prevent water damage to adjacent construction should a leak occur or during routine maintenance 5 DO NOT place this boiler in a location that would restrict the introduction of combustion air into the unit or subject it to a negative pressure unless the combustion air is piped from the outside see the COMBUSTION AIR VENTILAT...

Page 4: ...ely communicate with the outdoors must be present The upper opening must be within 12 in 300 mm of but not less than 3 in 80 mm from the top of the enclosure The bottom opening must be within 12 in 300 mm of but not less than 3 in 80 mm from the bottom of the enclosure Where directly communicating with the outdoors or communicating with the outdoors through vertical ducts each opening shall have a...

Page 5: ... serving a separate appliance designed to burn solid fuel A barometric damper or blast gate as required must be installed if a Category II vertical vent system produces a negative draft in excess of 0 15 in 3 8 mm WC at the flue outlet Size the vent system per local codes and the vent pipe manufactuers requirements using generally accepted engineering practices For Category II and IV appliances th...

Page 6: ...s than 4 ft 1 3 m horizontally from and in no case above or below unless a 4 ft 1 3 m horizontal distance is maintained from electric meters gas meters regulators and relief equipment and not less than 7 ft 2 3 m above adjacent public walkway The bottom of the vent terminal s shall be located at least 5 ft 1 5 m above the air intake terminal s unless there is a 5 ft 1 5 m distance between them Use...

Page 7: ...sulated with insulation rated for 400 F 204 C Structural penetrations must be made using approved fire stops The top of a vertical vent system must extend at least 51 2 ft 1 8 m above the roof surface that it passes through 4 ft 1 3 m above the intake air cap see Figure 4 In addition the vent system must conform to the dimensions shown in Figure 4 The penetration point in the roof must be properly...

Page 8: ...pproved Stainless Steel Vent Manufacturers CAT II IV Table Y Approved Intake Exhaust Terminations CAT IV Sidewall Horizontal Direct Vent The ATH KN Series Plus is supplied with a factory installed DuraVent FastNSeal flue outlet adapter A manufacturers supplied stainless steel transition piece must be used when installed with different vent systems Do not mix vent systems of different manufacturers...

Page 9: ...SDA 10FCSPKA2 Model Size Heatfab Saf T Vent Security Chimneys Secure Seal Jeremias Transition Adapter Flue Transition Adapter Flue Transition Adapter Flue 6 9501MAD EZ GC Cl Plus SS5FFNSAU SSD5FFNSAUK SS SSD DWGV5 RCIS DWKL SWKL DWGV SWGV 10 16 9601MAD SS6FFNSAU SSD6FFNSAUK DWGV6 RCIS 20 26 9801MAD SS8FFNSAU SSD8FFNSAUK DWGV8 RCIS 30 40 91001MAD SS10FFNSAU SSD10FFNSAUK DWGV10 RCIS Model Size VAN P...

Page 10: ...ry for vertical heights beyond 60 ft B D C F FLUE VENT THERMAL SPILL SWITCH DOUBLE ACTING BAROMETRIC DAMPER ALL CONNECTIONS TO BE T WYE MULTIPLE BOILER NEGATIVE DRAFT VENTING INSTALLATION AIOM 105_B BOILER 1 BOILER 2 IF REQUIRED BOILER 4 IF REQUIRED BOILER 3 IF REQUIRED VERTICAL CHIMNEY VENTING VERTICAL VENTING MULTIPLE BOILER INSTALLATIONS IT IS RECOMMENDED THAT THE BOILERS NEAREST THE VERTICAL C...

Page 11: ...m MINIMUM TO ADJACENT BUILDING PITCH PIPE DOWN TOWARDS TERMINAL CAP 1 4 IN FT 20 mm m EXHAUST COMBUSTION AIR 1 5 FT 0 5 m MINIMUM DISTANCE FROM INTAKE TO MAXIMUM SNOW LINE Y MINIMUM BETWEEN TERMINALS X MINIMUM BETWEEN TERMINALS CENTER LINE REFER TO TABLE Y FOR APPROVED VENT TERMINATION AND DIMENSIONAL DATA NOTES 1 DIMENSIONS ARE IN INCHES IN FEET FT MILIMETERS mm OR METERS m AS SHOWN WARNING When ...

Page 12: ... Cast Iron Condensing Boilers Installation Manual Figure 4 Vertical Air Intake and Venting for Direct Vent System Figure 5 Combination Direct Vent Systems AIOM 003_C COMBUSTION AIR EXHAUST MAXIMUM MAXIMUM ...

Page 13: ... POSITIVE PRESSURE CATEGORY IV In this configuration the boiler blower is used to push the flue products vertically to the outdoors see Figure 7 The air for combustion is taken from the space in which the unit is installed The applicable instructions under the COMBUSTION AIR VENTILATION SECTION must be followed The vent guidelines under the Vertical Direct Vent Systems section must also be followe...

Page 14: ...m manufacturer s instructions must be followed Multiple boiler vent systems must be designed and verified by a qualified professional and stack manufacturer The vent system must prevent backflow of exhaust gas through idle boilers When more than one appliance is connected to the same chimney system the system must be large enough to safely vent the combined output of all of the appliances Table 5 ...

Page 15: ...e l espace où les appareils toujours raccordés du système d évacuation sont installés et les autres espaces du bâtiment Mettre en marche les sécheuses tous les appareils non raccordés au système d évacuation commun et tous les ventilateurs d extraction comme les hottes de cuisinère et les ventilateurs des salles de bain S assurer que ces ventilateurs fonctionnent à la vitesse maximale Ne pas faire...

Page 16: ... 61 cm from the center line of the terminal E Clearance to unventilated soffit F Clearance to outside corner G Clearance to inside corner H Clearance to each side of center line extended above meter regulator assembly I Clearance to service regulator vent outlet 3 ft 91 cm J Clearance to nonmechanical air supply inlet to building or the combustion air inlet to any other appliance 6 in 15 cm for ap...

Page 17: ... 3 kW and 100 000 Btuh 30 kW 36 in 91 cm for appliances 100 000 Btuh 30 kW 4 ft 1 2 m below or to side of opening 1 ft 300 mm above opening C Clearance to permanently closed window D Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 ft 61 cm from the center line of the terminal E Clearance to unventilated soffit F Clearance to outside corner G Cle...

Page 18: ... or balcony is fully open on a minimum of two sides beneath the floor NOTES 1 In accordance with the current CSA B149 1 Natural Gas and Propane Installation Code 2 In accordance with the current ANSI Z223 1 NFPA 54 National Fuel Gas Code 3 If locally adopted installation codes specify clearances different than those illustrated then the most stringent clearances must prevail Per local installation...

Page 19: ...th the factory supplied outdoor hood air intake adapter with filter and exhaust terminal see Figure 8A Multiple units must be spaced per Figure 8B The boiler must be at least 2 ft 62 m from any door window or gravity air inlet into any building and at least 3 ft 1 m from any overhang unless local codes dictate differently Avoid locations where wind deflection off of adjacent walls buildings or shr...

Page 20: ...e If the system is using Glycol the of glycol mixturemustbeentered TheSIKAFlowsensor is limited to 194 F 90 C water temperature 145 psi operating pressure and a 50 glycol mixture If the return water temperature rises above194 F 90 Ctheboilerwillshutdown For applicationsoutsidetheserequirements please consult Manufacturer Reference the HeatNet IOM for menu instructions Air Vent The factory mounted ...

Page 21: ...d the system must be protected by the addition of a corrosion inhibitor per the chemical supplier s instructions For systems requiring glycol for freeze protection use a glycol water mix that prevents foaming Air entrapped within foam significantly decreases heat transfer and can result in damage to the sections Products such as DOWFROST DOWTHERM UCARTHERM or an equivalent product must be used to ...

Page 22: ... the boiler Flow must be properly accounted for in the design of primary secondary systems In order to prevent boiler s short cycling the system flow must be equal to or higher than the boiler s local flow Systems using multiple boilers can be installed using a primary secondary manifold system Figure 13 Piping For Use With Cooling Units The boiler when used in connection with a refrigeration syst...

Page 23: ... installed at a minimum of 12 from primary loop tee FOR HEAT NET OPERATION A SENSOR IS REQUIRED AND INSTALLED AT A MINIMUM OF 12 FROM PRIMARY LOOP TEE AIOM 112_B TANGENTIAL TYPE AIR SEPARATOR AQUASTAT HEAT NET SENSOR PRESURE REDUCING VALVE PRESURE RELIEF VALVE EXPANSION TANK THERMOMETER BACKFLOW PREVENTION DEVICE GATE VALVE PUMP SYSTEM RETURN AIR SEPARATOR TYPICAL LOCATION AIR SEPARATOR ALTERNATE ...

Page 24: ... to an acceptable temperature before it s supplied for domestic use The mixing valve MUST be set to prevent a scald injury from occurring see the caution against scalding above Storage of water for domestic use above 140 F 60 C will provide an increased quantity of tempered water and help prevent the growth of water born bacteria Figure 14 Typical Single Boiler with Indirect Storage Tank Piping AI...

Page 25: ...ES 1 LOCATE HEAT NET SENSOR WITH WELL IN LOWER 1 3 OF TANK INSTALL SENSOR WITH HEAT SENSING COMPOUND 2 THERMAL EXPANSION TANK MAY BE REQUIRED CHECK LOCAL CODES 3 COMMON PIPING MUST BE SIZED FOR MAXIMUM COMBINED HEATER FLOW 4 HOT WATER TANK SHOULD BE EQUIPPED WITH A COMBINATION TEMPERATURE PRESSURE RELIEF VALVE VALVE SHALL DISCHARGE TO A SAFE PLACE WITH AN AIR GAP REFER TO LOCAL CODES 5 MA CODE REQ...

Page 26: ... pump If a condensate neutralization device is required by local code it must be positioned prior to boiler room drain Fill the condensate trap with water check and maintain water level in trap during operation prior to start up GAS SUPPLY PIPING Check the boiler rating plate to make sure that the boiler is for the type of gas that will be used If it isn t do not connect the boiler to the gas supp...

Page 27: ...d the latest revision of the National Electrical Code ANSI NFPA 70 Installation should also conform with CSA C22 1 Canadian Electrical Code Part I if installed in Canada Aseperate circuit breaker must be installed per boiler if required the optional local pump FLAmust be incorporated and sized accordingly A properly rated shut off switch should be located at the boiler The boiler must be grounded ...

Page 28: ... make up water valve and check and clean the strainers and make up water pressure reducing valve Open the make up water valve and adjust the system pressure if necessary The system should be checked and bled after three days of operation OPERATING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE OPERATING ONLY QUALIFIED LICENSED SERVICE TECHNI CIANS SHALL START TROUBLESHOOT AND SERVICE THIS APPLIANCE WITH...

Page 29: ... the power switch on the front of the boiler to on It will light up when the power is on If all interlocks are properly closed the display will say Standby Figure 18 13 Slide the HeatNet controls low fire switch on the HeatNet control board to the low fire position 14 The boiler will begin the start sequence 15 When the main display reads PILOT RUNNING and the flame current is 5VDC switch the Hone...

Page 30: ...ed for high altitude installations 20 Switch the Honeywell 7800 back to run 21 Create a minimum input demand as before enable low fire switch on the HeatNet board The boiler will begin the start sequence 22 Monitor the flame current on the 7800 No flame current should be detected and the 7800 should lock out If flame current is detected at any time up to the 7800 locking out the 120V wiring on the...

Page 31: ...ote 12 Turn the power switch on the front of the boiler to on It will light up when the power is on If all interlocks are properly closed the display will say Standby Figure 18a 13 Slide the HeatNet controls low fire switch on the HeatNet control board to the low fire position 14 The boiler will begin the start sequence 15 When the main display reads PILOT RUNNING and the flame current is 5VDC swi...

Page 32: ...hile approaching the desired input to avoid overshoot in zero adjustment Wait for combustion to stabilize Confirm the CO2 is between 7 0 8 0 Adjust the low fire CO2 if necessary by opening the low fire adjustment door located on the forward side of the main gas valve Figure 17 A final low fire combustion adjustment will be done further into the startup procedure i When finished select the green ch...

Page 33: ...adjustment is satisfactory press the green check mark to save the setting The boiler will return to low fire 30 Setting the Min Air Shutter and Low Fire values a Verify the S2 Calibration switch located on the 3 0 HeatNet board is in the CAL position Then select Adjust on the Min Air Shutter tab The value will turn green indicating that an adjustment can be changed b Wait for combustion to stabili...

Page 34: ...CO2 flue gas combustion values are for Reference Only see O2 Sensor location Figure 18a The O2 Sensor calibration period may take up to 6 hrs of steady state operation variations in readings may be observed A calibrated flue gas analyzer must be used for final adjustment Failure to verify combustion could result with improper conditions that could lead to personal injury death or property damage d...

Page 35: ...all electric power to the boiler if service is to be performed 3 Close the manual main and pilot gas shut off valves COMMENT COUPER L ADMISSION DE GAZ DE L APAREIL 1 Réglez le thermostat à la température la plus basse 2 Coupez l alimentation électrique de l appareil s il faut procéder à l entretien 3 Fermer la vanne manuelle d arrêt d alimintation de gaz SEQUENCE OF OPERATION NO DEMAND Standby 1 T...

Page 36: ...ly form frost on the air handling components of the boiler Refer to 2015 ASHRAE Cold Climate Buildings Design Guide Table 12a Pressure Signal P NG LP with High Turndown Option Firing Rate KN6 KN10 KN16 KN20 KN26 KN30 KN40 Delta P in WC Delta P in WC Delta P in WC Delta P in WC Delta P in WC Delta P in WC Delta P in WC Fuel NG LP NG LP NG LP NG LP NG LP NG LP NG LP 100 7 30 9 25 10 40 11 60 11 80 1...

Page 37: ...t String to Ignition Control Have We received the BLOWER signal CALL FOR HEAT PRE_PURGE Interlocks OK Are we below the Temp Band YES fire the boiler NO Send 120 VAC BLOWER signal Limits OK Operate Blower Motor 55 LIMITS After 10 Seconds send PILOT signal BLOWER PILOT signal PILOT PILOT Ignition J4 Pins 4 8 Operate Blower Motor 32 FLAME Operate Blower Motor 0 After 10 Seconds send MAIN VALVE signal...

Page 38: ...igure 20 and connect a manometer having a minimum range of 6 in 154 mm WC to it Open the pilot gas shut off valve With the unit powered generate a call for heat When the prepurge is complete the ignition pilot trial will begin At this point put the Honeywell 7895C test switch in the test position The control will hold in the ignition pilot sequence allowing you to check the pressure Verify the pil...

Page 39: ... burn 10 cu ft of gas at full fire 5 Insert the heating value and the time in seconds into the formula below 6 Input 10 seconds Btu per cu ft 3600 7 If the computed rate exceeds the desired input follow section operating instructions to make the appropriate adjustments Never increase the input to the boiler above that for which it is rated Doing so can cause premature failure of the boiler Low Wat...

Page 40: ... Flush the drain trap and refill with 50 water glycol mix to prevent evaporation in the trap Controls Use the BOILER OPERATION and CHECKING AND ADJUSTMENT sections of this manual for reference 1 Check the operating controls for proper operation 2 The probe on a probe low water cut off must be removed cleaned and inspected at least once a year Ensure that the low water cutoffs operate properly If n...

Page 41: ...VICE PANEL ORANGE BLUE ORANGE SWITCH SET POINTS IN INCHES OF WATER COLUMN SWITCH FOR KN 5 1 PS1 BLOWER PROVE 0 10 PS2 BLOCKED FLUE 5 50 PS3 BLOCKED INLET 3 00 BLUE PURPLE INSIDE SERVICE PANEL GAS VALVE ASSEMBLY PILOT GAS TRAIN PS3 BLOCKED INLET PRESSURE SWITCH REAR FRONT FRONT P2 REAR P1 PS1 BLOWER PROVE PRESSURE SWITCH REAR FRONT PS2 BLOCKED FLUE PRESSURE SWITCH IGNITOR BLOCK ASSEMBLY UV SCANNER ...

Page 42: ...LOW PROVE 1 2 3 4 5 6 7 8 Low Fire Hold Fires the boiler at the minimum rate while in Calibrate This functions exactly as the T1 input Calibrate Allows adjustment of the Minimum Fire Maximum Fire and Pilot Ignition settings Combustion provingswitch from Combustion Air Damper Remote 120 VAC Operator USB and Flashdrive Ports Used by HeatNet Pro and updatingfirmware Local Pump or Power Open Power Clo...

Page 43: ... Operating Instructions Steps 1 10 2 Disable any external call for heat and toggle the remote local switch to REMOTE follow section Operating Instructions selected turndown procedure 3 Ignition and pilot adjustment Toggle the LOW FIRE switch to cycle the boiler then hold at trial for pilot ignition follow section Operating Instructions selected turndown procedure 4 Set pilot pressure follow sectio...

Page 44: ...TION 10 1 MAXIMUM CALIBRATION N A N A TACHOMETER RPM RPM BLOWER CLAMP CALIBRATION 10 1 N A COMMISSIONING THE BOILER THE DELTA T BETWEEN THE HEATER IN LET AND OUTLET IS CRITICAL TO PROP ER FLOW BEFORE YOU LEAVE THE JOB SITE YOU MUST RECORD THE DELTA T THIS READING SHOULD NOT EXCEED 100o F 55o C NOR BE LOWER THAN 20o F 11 1o C DELTA T UNIT CYCLED MINIMUM OF 15 TIMES CUSTOMER INSTRUCTED ALL COVERS RE...

Page 45: ...45 Cast Iron Condensing Boilers Installation Manual Figure 24 KN6 10 16 20 26 30 and 40 ...

Page 46: ...46 Cast Iron Condensing Boilers Installation Manual Figure 25 KN6 10 16 20 26 30 and 40 ...

Page 47: ...47 Cast Iron Condensing Boilers Installation Manual Figure 26 Gas Train Drain Pan ...

Page 48: ...48 Cast Iron Condensing Boilers Installation Manual Figure 27 Control Panel Figure 28 Secondary Heat Exchanger Assembly ...

Page 49: ... 1 1 1 1 1 1 8 Return Sensor w Well 02 4284 1 1 1 1 1 1 1 9 Filter Box Cover 03 00370 002 1 1 03 00370 001 1 1 1 1 03 00370 000 1 10 Sight Glass 60 4280 1 1 1 1 1 1 1 Sight Glass Gasket 05 00103 001 1 1 1 1 1 1 1 Inner Sight Glass Gasket 59 1064 1 1 1 1 1 1 1 11 Air Filter 20 00016 002 1 1 20 00016 001 1 1 1 1 20 00016 000 1 12 Filter Box Weldment 75 00305 002 1 1 74 00305 001 1 1 1 1 74 00305 000...

Page 50: ...2 003 1 1 09 00002 002 1 1 09 00002 001 1 1 09 00002 005 1 16 Blower Replacement Kit 75 00567 1 1 75 00572 001 1 1 75 00573 001 1 1 75 00585 001 1 NS Clear RTV Sealant 66 00103 001 3 3 3 3 3 3 3 NS Gasket Blower Filter Box 06 00018 001 1 1 NS Gasket Blower Blower Adapter 06 00016 001 1 1 06 00008 001 1 1 1 1 1 17 Shutter Box 75 00355 001 1 1 1 1 1 1 75 00355 000 1 18 Upper Cover 75 00255 001 1 75 ...

Page 51: ...1 1 1 1 1 1 1 1 22 Condensate Trap Assembly 75 00234 002 1 1 1 1 1 1 1 Condensate Trap Cap 04 00110 1 1 1 1 1 1 1 22a Condensate Trap Assembly 10 1 75 00234 004 1 1 1 1 1 1 1 22b Switch Level 14 00401 001 1 1 1 1 1 1 1 23 Manual Shutoff Valve 1 02 1575 1 1 Manual Shutoff Valve 1 1 2 02 1578 1 1 1 1 Manual Shutoff Valve 2 84 01300 006 1 24 Pilot Gas Regulator 11 00301 001 1 1 1 1 1 1 25 Pilot Gas V...

Page 52: ... 1 1 1 1 67 Air Pump 09 1518 1 1 1 1 1 1 1 NS Touchscreen Overlay 82 00410 001 1 1 1 1 1 1 1 NS HeatNet Overlay 82 00412 013 1 82 00412 012 1 82 00412 011 1 82 00412 010 1 82 00412 009 1 82 00412 008 1 82 00412 007 1 NS Rating Label 82 00004 001 1 1 1 1 1 1 1 69 Secondary Heat Exchanger 52 00151 003 1 1 52 00151 002 1 1 52 00151 001 1 1 52 00151 000 1 NS Gasket 06 00028 001 2 2 2 2 2 2 06 00028 00...

Page 53: ...aust vent termination is less than seven 7 feet above finished grade in the area of the venting including but not limited to decks and porches the following requirements shall be satisfied 1 INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas fueled equipment the installing plumber or gasfitter shall observe that a hard wired carbon monoxide...

Page 54: ...n practices The inlet outlet water temperature differential across the boiler heat exchanger must not exceed 100 degrees F System water quality dissolved solids must be less than 500 ppm and no greater than 300 ppm hardness Suspended solids such as magnetite Iron Oxides must be flushed from the system prior to commissioning the boiler s In addition pH levels must be in the 6 5 11 range Failure to ...

Page 55: ...55 Cast Iron Condensing Boilers Installation Manual ...

Page 56: ...IN UNITED STATES 260 NORTH ELM ST WESTFIELD MA 01085 413 564 5515 IN CANADA 7555 TRANMERE DRIVE MISSISSAUGA ONT L5S 1L4 905 670 5888 www knseries com ...

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