3
Gas-Fired Direct Vent Cast Iron Boilers – Field Assembly Instructions
ATTENTION:
Use of an approved dust respirator is
strongly recommended when handling the
insulating components of the boiler.
Electrical shock hazard — Disconnect all
electrical power sources to the boiler before
making any electrical connections.
Label all wires prior to disconnection when
servicing controls. Wiring errors can cause
improper and dangerous operation! Verify
proper operation after servicing.
Failure to comply with the above could result in
severe personal injury, death or substantial
property damage.
The electrical connections to 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 rated shut-off switch should
be located at the boiler. The boiler must be
grounded in accordance with the authority
having jurisdiction, or if none, the latest revision
of the National Electrical Code, ANSI/NFPA-70.
Line voltage fi eld wiring of any controls or other
devices must use copper conductors with a
minimum size of #14 awg. Use appropriate
wiring materials for units installed outdoors.
DO NOT open any gas valve, or attempt to fi re
the boiler, until all boilers have been set up and
verifi ed following the instructions in the KN
Series Gas Boiler Installation & Operating
Instructions.
Failure to comply could cause a boiler failure,
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" boards (used for cushioning when
seating push nipples)
5. Two 18 inch pipe wrenches (plus 2 inch x 2 feet
cheater pipe)
6. Crescent wrenches, 18 inch or larger, may be used for
tightening the draw rod nuts (NOT tie rods). (See
Step 16, page 10 for draw rod instructions.)
7. Torque wrench (at least 30 foot-pound capacity)
8. Deep socket, 11/16 inch for use with torque wrench
9. Standard hand tools.
10. Wire, wire nuts, electrical hand tools (crimper, stripper,
etc.).
Boiler Components And Shipping Information
Check the contents of the skids against the
Bill of Materials/Checklist shipped with the
boiler. Use the Checklist to locate specifi c items
throughout the assembly process. Content
your Hydrotherm supplier if you discover any
components damaged or missing.
The boiler is shipped in two skids and one crate. See the
contents of the crates and skids in Figure 2, page 23.
Sealants, lubricants and adhesives supplied with
boiler (see Figure 2, page 23 for location)
Use gloves when working with these products
as specified in these instructions and in the
product instructions.
1. Silicone RTV-6500 HiTemp: 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: 8-oz jar (for mixing with 30-wt
motor oil, used as lubricant for push nipples)
4. Fast-Tack 87: (1) 13-oz spray can (for securing fl ue
baffl es to sections)
