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KN SERIES GAS BOILER
INSTALLATION & OPERATING
MEA #444-05-E
DESIGNED AND TESTED ACCORDING TO A.S.M.E. BOILER AND PRESSURE VESSEL
CODE, SECTION IV FOR A MAXIMUM ALLOWABLE WORKING PRESSURE OF 100 PSI,
700 kPa, WATER.
WARNING: If the information in this manual is not followed exactly, a fi re or explosion
may result causing property damage, personal injury or loss of life.
Do not store or use gasoline or other fl ammable vapors and liquids in the vicinity of
this or any other appliance.
WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch. Do not use any phone in your building.
• Immediately call your gas supplier from a neighbor's phone. Follow the gas
supplier's instructions.
• If you cannot reach your gas supplier, call the fi re department.
Installation and service must be performed by a qualifi ed installer, service agency or
the gas supplier.
CAUTION: Do not use automotive anti-freeze in the boiler waterways. If the use of antifreeze is necessary an
anti-freeze specifi cally formulated for hydronic heating systems must be used or damage to the boiler may
occur voiding the warranty!
INSTALLER, THESE INSTRUCTIONS TO BE AFFIXED ADJACENT TO THE BOILER / WATER HEATER.
CONSUMER, RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE PURPOSES.
Advanced Thermal Hydronics
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) 672-2991 • FAX (905) 672-2883
WITH
INSTRUCTIONS
www.hydrothermkn.com
CONTROL
MASS Plumbers #G1-06-04-28
IOMKN2-508
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Summary of Contents for HydroTherm KN SERIES
- Page 1 IOMKN2-508 KN SERIES GAS BOILER WITH CONTROL INSTALLATION & OPERATING INSTRUCTIONS MEA #444-05-E MASS Plumbers #G1-06-04-28 DESIGNED AND TESTED ACCORDING TO A.S.M.E. BOILER AND PRESSURE VESSEL CODE, SECTION IV FOR A MAXIMUM ALLOWABLE WORKING PRESSURE OF 100 PSI, 700 kPa, WATER.
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Page 2: Table Of Contents
This manual covers the application, installation, The owner should maintain a record of all service work operation and maintenance of a KN series boiler. performed with the date and a description of the work done. Include the name of the service organization for To obtain the safe, dependable, effi... -
Page 3: Ratings & Capacities
KN INSTALLATION AND OPERATION INSTRUCTIONS Page 3 RATINGS & CAPACITIES 5. DO NOT place this boiler in a location that would restrict the introduction of combustion air into the Before installing the KN boiler check the rating plate to unit or subject it to a negative pressure unless the ensure that the unit has been sized properly for the job. - Page 4 KN INSTALLATION AND OPERATION INSTRUCTIONS Page 4 Buildings will require the installation of a fresh air duct Where communicating with the outdoors through hori- or other means of providing make-up air if the intake zontal ducts, each opening shall have a minimum free air option isn't used.
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Page 5: Venting Guidelines
KN INSTALLATION AND OPERATION INSTRUCTIONS Page 5 Direct Intake Air Option - Vertical Table 5 - Horizontal Intake & Vent System The maximum equivalent length for the vertical intake Components air pipe is 80 ft, 19.7 m. Each 90° mitered elbow and Company Description Part Number... - Page 6 KN INSTALLATION AND OPERATION INSTRUCTIONS Page 6 VENT SYSTEM OPTIONS Heat-Fab, Inc. 38 Hayward Street The KN may be vented the following ways: Greenfi eld, MA 01301, (800) 772-0739. 1) Direct Vent - Positive Pressure, Category IV uses a vent system certifi ed to UL 1738 for installations Z-Flex U.S., Inc.
- Page 7 KN INSTALLATION AND OPERATION INSTRUCTIONS Page 7 When running horizontal combustion air and venting for The maximum equivalent length for the vertical vent pipe single or multiple units, exhaust and combustion air is 80 ft, 19.7 m. Each 90° elbow and the intake air cap terminals must be installed on the same plane (outside are equal to 10 ft, 3.3 m of straight pipe.
- Page 8 KN INSTALLATION AND OPERATION INSTRUCTIONS Page 8 KN-10 Multiple Boiler Venting Category II Venting (Negative) "B" ALL CONNECTIONS TO BE "T-WYE" DOUBLE ACTING "C" BARAMETRIC DAMPER "A" THERMAL SPILL SWITCH "D" Table 1 - Common Vent Sizes 6" AIR INLET 6"...
- Page 9 KN INSTALLATION AND OPERATION INSTRUCTIONS Page 9 Figure 1 - Horizontal Air Intake and Venting for a Single Direct Vent System Figure 2 - Horizontal Air Intake and Venting for Multiple Direct Vent Systems...
- Page 10 Page 10 KN INSTALLATION AND OPERATION INSTRUCTIONS Figure 3 - Vertical Air Intake and Venting for Direct Vent System Figure 4 - Combination Direct Vent Systems...
- Page 11 KN INSTALLATION AND OPERATION INSTRUCTIONS Page 11 SIDE WALL VENT The air for combustion is taken from the space in which the unit is installed. The applicable instructions under POSITIVE PRESSURE, CATEGORY IV the COMBUSTION AIR & VENTILATION SECTION In this confi guration the boiler blower is used to push the must be followed! The vent guidelines under the fl...
- Page 12 Always provide a minimum clearance of 6 in, 152 mm Multiple KN’s can be vented into a single vertical between single wall vent pipe and any combustible chimney system. Refer to HydroTherm KN-10 Venting materials. page 7. Consult factory for multiple KN-6 and KN-20 venting applications.
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Page 13: Common Vent Systems
KN INSTALLATION AND OPERATION INSTRUCTIONS Page 13 COMMON VENT SYSTEMS Dans la mesure du possible, fermer toutes les portes et les fenêtres du bâtiment et toutes les portes entre If an existing boiler is removed from a common venting l'espace où les appareils toujours raccordés du system, the common venting system may then be too système d'évacuation sont installés et les autres large for the proper venting of the remaining appliances... -
Page 14: General Piping Requirements
KN INSTALLATION AND OPERATION INSTRUCTIONS Page 14 GENERAL PIPING REQUIREMENTS Figure 8 - Relief Valve Piping CAUTION: Improper piping of this boiler will void the manufacturer’s warranty and can cause boiler failure resulting in fl ooding and extensive property damage! NOTE: Shut off valves and unions should be installed at the inlet and outlet connections of the boiler to provide for isolation of the unit should... - Page 15 KN INSTALLATION AND OPERATION INSTRUCTIONS Page 15 Cleaning Boiler Expansion Tank & Air Separator Installer must fl ush and clean out boiler cavity to ensure An expansion tank or other means to control thermal unit is cleansed of various impurities. expansion must be installed in the heating system.
- Page 16 KN INSTALLATION AND OPERATION INSTRUCTIONS Page 16 Figure 10 - Typical Multiple Boiler Reverse Return Piping (RECOMMENDED) (Careful consideration as to minimum boiler and system water fl ow rates must be taken. Please consult our local manufactures representative for assistance.) SYSTEM RETURN Motorized ...
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Page 17: Domestic Water Supply Piping
KN INSTALLATION AND OPERATION INSTRUCTIONS Page 17 NOTE: The storage tank must be located as close DOMESTIC WATER SUPPLY PIPING to the boiler as possible to prevent excessive head loss which will reduce fl ow. CAUTION: Proper controls must be used to prevent water supplied for domestic use from exceeding Expansion Tank 130°F, 54°C or a scald injury will occur! When higher... -
Page 18: Condensate Piping
KN INSTALLATION AND OPERATION INSTRUCTIONS Page 18 Figure 14 - Typical Multiple Boiler with Indirect Storage Tank Piping NOTE: Not all system valves may be shown. Consult local codes for additional system components which may be necessary. CONDENSATE PIPING The condensate trap provided with the boiler must be KN-6 and KN-10 Condensate Drain attached to the bottom pan and piped to a suitable fl... -
Page 19: Gas Supply Piping
Always use a pipe sealant that is suitable for type of gas available at the installation site, call your use with LP gas. HydroTherm representative to resolve the problem. Table 9 - Gas Pipe Capacity Table 9 should be used to ensure that the gas supply Maximum pipe capacity in ft /hr based on 0.60 specifi... -
Page 20: Electrical Wiring
KN INSTALLATION AND OPERATION INSTRUCTIONS Page 20 Table 10 - Equivalent Pipe Length Chart Whenever the gas supply piping is pressure tested the boiler gas controls must be protected. If the test Type of pipe fi tting Nominal pressure is equal to, or less than 1/2 psig, 3.5 kPa Iron Pipe 90°... -
Page 21: Operating Instructions
KN INSTALLATION AND OPERATION INSTRUCTIONS Page 21 Should overheating occur or the gas supply fail to shut OPERATING INSTRUCTIONS off, turn off the manual gas control valve to the FOR YOUR SAFETY READ BEFORE OPERATING. appliance. Do Not interrupt water fl ow through the ONLY QUALIFIED LICENSED SERVICE TECHNI- boiler. - Page 22 KN INSTALLATION AND OPERATION INSTRUCTIONS Page 22 Operating Instructions Figure 16 - Control Panel 1. STOP! Read the safety information above. If, at any time, the appliance will not operate properly, follow the instr uctions “TO TURN OFF GAS TO APPLIANCE”...
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Page 23: Sequence Of Operation
KN INSTALLATION AND OPERATION INSTRUCTIONS Page 23 COMMENT COUPER L'ADMISSION DE GAZ DE 25. Jumper the "AA" terminals. The boiler input will rise to its maximum input, "Run 100%", see Fig. 22. L'APAREIL 1. Réglez le thermostat à la température la plus basse. 26. -
Page 24: Ignition Troubleshooting
KN INSTALLATION AND OPERATION INSTRUCTIONS Page 24 KN Series "Heat Net Control" Troubleshooting (Firing the KN Boiler) Variable Frequency KN Control Functions Ignition Contrrol Hand Shake Drive Ignition Sequence (Honeywell S7800) INPUTS: DISPLAY: 1. MODBUS STANDBY CALL FOR 2. AA 3.Heat Demand... - Page 25 KN INSTALLATION AND OPERATION INSTRUCTIONS Page 25 Troubleshooting A Startup Symptom Identify Source Check Action An Interlock is tripped. 1. Is it a 24 VAC Interlock? 1. All 24 VAC Interlocks are 1.Use a multimeter and check located on J11A and J11B. for 24 VAC on J11A,J11B to Examples of 24 VAC Interlocks: identify which interlock has...
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Page 26: Checking & Adjustment
Page 26 KN INSTALLATION AND OPERATION INSTRUCTIONS CHECKING, ADJUSTMENT & OPERATION CAUTION: Never force the regulator adjustment screw beyond the stop limits or damage to the regulator will occur! Spark Gap The gap has to be measured and adjusted with the Figure 18 - Pilot Flame igniter removed from the boiler. -
Page 27: Diagnostics
KN INSTALLATION AND OPERATION INSTRUCTIONS Page 27 Ignition Safety DIAGNOSTICS To test the ignition safety shutoff device, close the The KN has a display that indicates the sequence of manual shutoff valve 1 (Figure 15) in the gas supply line. operation, Figure 16. -
Page 28: Maintenance
KN INSTALLATION AND OPERATION INSTRUCTIONS Page 28 MAINTENANCE Controls Use the BOILER OPERATION and CHECKING AND ADJUSTMENT sections of this manual for reference. WARNING: Disconnect electrical power and 1. Check the operating controls for proper operation. close the manual gas shut off valve before performing maintenance or severe personal 2. -
Page 29: Troubleshooting
KN INSTALLATION AND OPERATION INSTRUCTIONS Page 29 TROUBLESHOOTING OPERATIONAL PROBLEM CORRECTIVE ACTION The "Power On" light doesn't illuminate. Ensure that proper voltage is being supplied to the unit Inspect the circuit breaker for the boiler circuit Check the light Ensure that the power switch operates properly and is wired correctly Lockout water limit is displayed with a call for heat. -
Page 30: Repair Parts
KN INSTALLATION AND OPERATION INSTRUCTIONS Page 30 Figure 20 - Exploded View - Front... - Page 31 KN INSTALLATION AND OPERATION INSTRUCTIONS Page 31 Figure 21 - Exploded View - Back...
- Page 32 KN INSTALLATION AND OPERATION INSTRUCTIONS Page 32 SERVICE AND REPLACEMENT PARTS LIST Model Size with Item Quantities Below Item Description Part # KN-6 KN-10 KN-20 BLOWER ASSEMBLY KIT BM-1507 BM-1508 FILTER BOX GASKET 59-1067 59-1072 30 VA TRANSFORMER 26-3208 PRESSURE SWITCH - HUBA 02-4881 FREQUENCY DRIVE 58-1846...
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Page 33: Wiring
KN INSTALLATION AND OPERATION INSTRUCTIONS Page 33 Figure 22... -
Page 34: Commonwealth Of Massachusetts
KN INSTALLATION AND OPERATION INSTRUCTIONS Page 34 MACODE-3 NOTICE! Commonwealth of Massachusetts Installation Requirements (a) For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above fi... - Page 35 KN INSTALLATION AND OPERATION INSTRUCTIONS Page 35 MACODE-3 NOTICE! Commonwealth of Massachusetts Installation Requirements In the Commonwealth of Massachusetts, the installation must be performed by a licensed plumber or gas fi tter. (b) Exemptions The following equipment is exempt from 248 CMR 5.08(2)(a) 1 through 4: 1.
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Page 36: Warranty
Hydrotherm KN Series Water Boiler Limited Warranty One-Year Warranty The “Manufacturer” warrants to the original owner at the original installation site that the KN- series modulating water boiler (“Product”) will be free from defects in material and workmanship for one (1) year from the date of installation or eighteen (18) months from the date of shipment from the factory which ever comes fi...
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