HydroTherm HeatNet KN-20 Field Assembly Instructions Download Page 2

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P/N 42-9551

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

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(English/French)

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Other manuals

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 installa-
tion 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.

Contents and information

Read before beginning the installation 5

Boiler ratings and specifications 6

Installation site preparation 7

Prepare the boiler 10

Water piping 11

Gas piping 18

Wiring a single boiler 20

Control setup 25

Vent piping (and air piping when used) 28

Condensate drain line 29

Fill and test the system 30

Starting the boiler 32

Annual start-up 41

Maintenance 42

Replacement parts 46

Appendix A — suggested wiring 48

Summary of Contents for HeatNet KN-20

Page 1: ...ly 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 repa...

Page 2: ...tNet 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 installa tion 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 Contents and information ...

Page 3: ...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 Attention Use of an approved dust respirator is strongly recommended when handling the insulating com ponents of the boiler Electrical shock...

Page 4: ...iTemp 3 10 oz 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 Skid 1 Cast iron sections front rear ...

Page 5: ...tions to move easily during draw up Step 3 Position the rear section Use leather gloves when lift ing or moving boiler sections Sections are heavy and can cause severe personal injury or death if mishandled Lift section using two people following the recommendations shown in Step 13 page 8 1 Identify the rear section its lower nipple port is on the right side when looking at the inside of the sect...

Page 6: ...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 recom mended for this procedure 1 Apply a bead of silicone RTV sup plied with boiler on the perimeter surfaces of the section an...

Page 7: ... dope oil mixture on the inner machined surfaces of the nipple ports 2 Avoid getting lubricant on the sili cone 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 nip ple makes a metal to metal seal with...

Page 8: ...e section 2 Handlers should lift with their legs to avoid back strain 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 ...

Page 9: ...ap 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 com pleted slide a draw rod through each of the four draw rod holes 2 Apply a washer and nut on each end and pull up f...

Page 10: ... condensate pan Rubber gloves are recom mended 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 conden sate 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...

Page 11: ...ided Step 25 Install inspection cover This could be done before the condensate drain pan is installed as shown in Step 22 page 10 The inspection cover is used for annual inspection of the section assembly and condensate handling compo nents 1 Assemble inspection cover flange and gasket 2 Position over condensate drain pan inspection opening 3 Secure with screws provided LEGEND for drawing at right...

Page 12: ...ront 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 recom mended when handling the insulating components of the boiler 1 Carefully place the burner gasket on the surface of the combustion chamber Step ...

Page 13: ...es 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 Step 31 Apply silicone RTV to top surface of section assembly Rubber gloves are recom mended for this procedure 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 ...

Page 14: ...ied 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...

Page 15: ...coax the pilot tube into position 4 After ensuring the pilot tube is aligned properly insert the pilot orifice assembly as shown 5 Screw the pilot orifice into the manifold hole securely DO NOT over tighten 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 S...

Page 16: ...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...

Page 17: ...lied with the igniter and conduit box installed Leather gloves are recom mended 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 App...

Page 18: ...rear of the boiler 2 Install the supply nipple in the tap ping 3 When the nipple is tightened it must be in the orientation shown the tapping must be on top with a tapping at the right and at the bottom 4 The 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 ...

Page 19: ...ectly 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 fac...

Page 20: ...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 ...

Page 21: ...he 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 gromm...

Page 22: ...ower assembly to the manifold blower flange 1 Use the nuts provided to secure the assembly to the manifold blower flange Step 60 Tighten gas line nipple clamps and gas train clamp 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 ...

Page 23: ...e De burr the aluminum tub ing 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 en sure it will be long enough after the jacket side panel is installed 3 Route the tubing through the hole in the f...

Page 24: ...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 1 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...

Page 25: ...e 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 recom mended 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 scr...

Page 26: ...t 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 Fig ure 1 page 28 Step 76 Connect motor wires See the wiring diagrams Figure 1 page 28 and Fig ure 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 w...

Page 27: ... 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 ...

Page 28: ...1 KN Series Gas fired direct vent cast iron boilers Field assembly instructions 1 2 7 Figure 1 Schematic wiring diagram numbered bullets show locations of wiring field connections all wires color coded and numbered ...

Page 29: ...29 P N 42 9551 KN Series Gas fired direct vent cast iron boilers Field assembly instructions 3 4 6 5 7 Figure 1 Continued ...

Page 30: ...30 P N 42 9551 KN Series Gas fired direct vent cast iron boilers Field assembly instructions Figure 2 Ladder wiring diagram ...

Page 31: ...31 P N 42 9551 KN Series Gas fired direct vent cast iron boilers Field assembly instructions Figure 2 Continued ...

Page 32: ...32 P N 42 9551 KN Series Gas fired direct vent cast iron boilers Field assembly instructions ...

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