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Page 5
KN INSTALLATION AND OPERATION INSTRUCTIONS
Read before beginning the installation
Codes and standards
Boiler compliances
The
K N
has been design certified by CSA for
use with natural and propane gas under the latest
revision of ANSI-Z21.13/CSA 4.9, Gas-Fired
Low Pressure Steam and Hot Water Boilers
and CAN1-3.1, Industrial and Commercial
Gas Fired Packaged Boilers. Each unit has been
constructed and hydrostatically tested for a
maximum working pressure of 100 psi (700
kPa), in accordance with Section IV of the
A.S.M.E. Boiler and Pressure Vessel Code.
Code compliances
All aspects of the boiler installation must con-
form 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.
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.
Commonwealth
of Massachusetts
If installing a
KN
boiler in the Commonwealth
of Massachusetts, you MUST FOLLOW the addi-
tional instructions contained in Advanced Thermal
Hydrodronics’ instruction sheet, MA CODE. If
you don’t have a copy, call your dealer or Advanced
Thermal Hydronics.
When installed in the Commonwealth of
Massachusetts, ensure the following:
• The boiler must be installed by a licensed
plumber or gas fitter.
• When antifreeze is used in the system, install
an approved pressure back-flow preventer.
• Per DOE mandate, the
KN-2
operator
control incorporates an automatic means
(outdoor/indoor air reset) of adjusting the
boiler water temperature for hot water
heating. The boiler must not operate without
the automatic means enabled.
Do not install or operate the boiler, or leave an installation, without complying with
all of the following, and with all information supplied in the boiler manuals.
Should overheating occur
• Do not shut off power to the circulators if the boiler should overheat or the gas supply fail
to shut off. Instead, shut off gas supply to the boiler with a manual valve in the gas supply
line.
When servicing or operating the boiler
• Disconnect electrical power when servicing the boiler to avoid potential for electrical
shock.
• Allow the boiler, components and water to cool before attempting to remove or handle
boiler parts.
• Do not add cold water to the boiler if it is hot. Allow the boiler to cool completely before
introducing cold water.
• Do not operate the boiler if any part has been under water.
• Follow the guidelines in the Maintenance section for dealing with fiberglass and ceramic
fiber materials.
You must have the following equipment
• Electric multimeter
• Ammeter
• Surface temperature gauge
• Metric Allen wrenches
• Pressure differential gauge or included DP manometer
• (3) Gas pressure meters: Two @ 0 – 14 inches WC; One @ 0 – 5 psi
• Combustion analyzer — You must use a combustion analyzer and follow all instructions
in this manual to correctly start-up the boiler. As prescribed in this manual, the O
2
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
• You must thoroughly flush the system, with the boiler isolated from the system, to remove
sediment. Existing systems, in particular, often contain large amounts of iron sediment.
Excess suspended solids in the water can lead to premature boiler failure.
• High efficiency equipment requires suitable water for reliable operation. Follow the ASME
recommendation for water treatment on hydronic applications that have dissolved solids
greater than 200 parts per million. Fill water must be softened if the solids concentration
is higher than this. See additional guidelines in this manual.
• Do not allow the boiler to operate with frequent introduction of make-up water. Correct
all problems causing leaks, relief valve weeping, or other factors that could cause fresh
water to be added.
• Do not use automotive anti-freeze in the boiler waterways. If the use of antifreeze is
necessary, an anti-freeze specifically formulated for hydronic heating systems must be
used or damage to the boiler may occur, voiding the warranty.
• On applications that use antifreeze or other low conductivity fluid in the water, provide
for increased water flow or ensure proper temperature rise.
Train the user
• Before leaving, review the User’s Information Manual with the boiler user/homeowner,
including the required maintenance to be performed by the user, the need for annual start-up/
maintenance by a qualified technician, the avoidance of combustion air blockage or contami-
nation, and never bringing or storing flammable products into the boiler area.
1
Before placing the boiler . . .
Verify boiler rating and gas supply
• Before installing the
K N
boiler, check the rating plate to ensure that the unit has been sized
properly for the job.
• Ensure that the boiler is 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.
• 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.
IMPORTANT
In accordance with Section 325 (f) (3) of the Energy Policy
and Conservation Act, this boiler is equipped with a feature
that saves energy by reducing the boiler water temperature as
the heating load decreases. This feature is equipped with an
override which is provided primarily to permit the use of an
external energy management system that serves the same
function.
THIS OVERRIDE MUST NOT BE USED UNLESS AT
LEAST ONE OF THE FOLLOWING CONDITIONS
IS TRUE:
• An external energy management system is installed that
reduces the boiler water temperature as the heating load
decreases.
• This boiler is not used for any space heating .
• This boiler is part of a modular or multiple boiler system
having a total input of 300,000 BTU/hr or greater.
• This boiler is equipped with a tankless coil.