KN Series Cast Iron Condensing Boilers

Product Information

Specifications:

• Model: KN series (KN-6, KN-10, KN-16, KN-20, KN-26, KN-30,
  KN-40)

• Material: Cast Iron

• Maximum Allowable Working Pressure: 100 psi, 700 kPa Water

• Gas Type: Natural Gas

• Design Certification: CSA

Product Usage Instructions

1. Installation:

Installation of the KN series boiler must be performed by a
qualified installer or service agency. Follow the installation
instructions provided in the manual carefully to ensure safe and
proper setup.

2. Operation:

Before operating the boiler, ensure that all installation steps
have been completed correctly. Refer to the control manual for
information on operating the boiler efficiently.

3. Maintenance:

Regular maintenance is essential for the efficient and long-term
operation of the boiler. Keep a record of all service work
performed, including dates and descriptions of the work done.

4. Safety Precautions:

Do not store flammable liquids near the boiler. If you detect a
gas leak, follow the safety instructions provided in the manual and
seek professional help immediately.

5. Warranty:

Use only approved anti-freeze specifically formulated for
hydronic heating systems to prevent damage to the boiler and
voiding of the warranty.

6. Compliance:

Ensure that the installation complies with local regulations and
codes, including ANSI Z223.1/NFPA 54 and ANSI/ASME CSD-1 for safety
and control devices.

Frequently Asked Questions (FAQ)

Q: Can the KN series boiler be installed on carpeting?

A: No, the KN series boiler may be installed directly on
combustible flooring but should never be placed on carpeting.

Q: What should I do if I smell gas?

A: If you smell gas, installation and service must be performed
by a qualified installer, service agency, or the gas supplier.
Follow the safety instructions provided in the manual.

KN-W-IOM2-0523 42-9554
Boiler Manual
Installation and Operation Instructions Cast Iron Condensing Boilers Whirlwind Models KN-6, KN-10, KN-16, KN-20, KN-26, KN-30 and KN-40
Also read and follow:
KN Control Manual
MEA #444-05-E MASS Plumbers #G1-06-04-28
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 dustfree 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. 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), MILIMETERS [mm] or METERS [m].
05/2023 Copyright 2014 Advanced Thermal Hydronics

Cast Iron Condensing Boilers ­ Installation Manual

If the information in this manual is not followed exactly, a fire or explosion may result causing property, personal injury or loss of life.
Do not store or use gasoline or other flammable 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 phone outside of the building. Follow the gas supplier’s instructions.
· If you cannot reach your gas supplier, call the fire department.
Installation and service must be performed by a qualified installer, service agency or the gas supplier.
Assurez-vous de bien suivre les instructions données dans cette notice pour réduire au minimum le risque d’incendie ou d’explosion ou pour éviter tout dommoge matériel, toute blessure ou la mort
Ne pas entreposer ni utiliser d’essence ou ni d’autres vapeurs ou liquides inflammables à proximité de cet appareil ou de tout autre appareil.
QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ:

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 20 Heating System Piping ………………………………. page 21 Domestic Water Supply Piping ……………………. page 24 Condensate Piping ……………………………………. page 26 Gas Supply Piping …………………………………….. page 26 Electrical Wiring………………………………………… page 27 Boiler Operation………………………………………… page 28 Operating Instructions ……………………………….. page 28 Sequence of Operation………………………………. page 35 Ignition Troubleshooting …………………………….. page 37 Checking & Adjustment ……………………………… page 38 Diagnostics ………………………………………………. page 39 Maintenance …………………………………………….. page 40 Pressure Switches…………………………………….. page 41 Wiring ……………………………………………………… page 42 Start-Up …………………………………………………… page 43 Repair Parts……………………………………………… page 44 Warranty ………………………………………………….. page 51
BEFORE YOU START
This manual covers the application, installation, operation and maintenance of a KN series boiler.

· Ne pas tenter d’allumer d’appareil.
· Ne touchez à aucun interrupteur; ne pas vous servir des téléphones se trouvant dans le bâtiment.

To obtain the safe, dependable, efficient operation and long life for which this boiler was designed, these instructions must be read, understood and followed.

· Appelez immédiatement votre fournisseur de gas depuis un voisin. Suivez les intructions du fournisseur.
· Si vous ne purvez rejoindre le fournisseur, appelez le service des incendies.
L’installation et l’entretien doivent être assurés par un installateur ou un service d’entretien qualifié ou par le fournisseur de gaz.
Failure to properly vent this unit can cause excessive amounts of carbon monoxide resulting in severe personal injury or death!
Do not use automotive anti-freeze in the boiler waterways. If the use of anti- freeze is necessary an anti-freeze specifically formulated for hydronic heating systems must be used or damage to the boiler may occur voiding the warranty!
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.

The KN boiler series has been design certified by CSA for use with natural gas under the latest revision of ANSI-Z21.13/CSA 4.9, Gas-Fired Hot Water 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.
All aspects of the boiler installation must conform 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.
If installed in the Commonwealth of Massachusetts, you MUST FOLLOW the additional instructions contained in Advanced Thermal Hydronics’ instruction sheet MACODE-3. Please refer to the back of this manual for required regulations.

INSTALLER, THESE INSTRUCTIONS TO BE AFFIXED ADJACENT TO THE BOILER.
CONSUMER, RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE PURPOSES.

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.

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Cast Iron Condensing Boilers ­ Installation Manual

The owner should maintain a record of all service work performed with the date and a description of the work done. Include the name of the service organization for future reference.
Direct all questions to your Advanced Thermal Hydronics distributor or contact the Advanced Thermal

The KN may be installed directly on combustible 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.

Hydronics Customer Service Department at: 260 North Elm Street, Westfield, MA 01085. Always include the model and serial numbers from the rating plate of the boiler in question.
RATINGS & CAPACITIES

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, see the “COMBUSTION AIR & VENTILATION” and “GENERAL VENTING GUIDLINES”.

Before installing the KN boiler check the rating plate to ensure that the unit has been sized properly for the job. Also ensure that the unit has been set up for the type of gas available at the installation site. Other important considerations are the availability of an adequate electrical supply, fresh air for combustion and a suitable vent system.
BOILER LOCATION

6. NEVER place this boiler in a location that would subject it to temperatures at or near freezing.
Never store combustible materials, gasoline or any product containing flammable vapors or liquids in the vicinity of the boiler. Failure to comply with this warning can result in an explosion or fire causing extensive property damage, severe personal injury or death!

1. This boiler is suitable for indoor/outdoor installations. Locate the boiler in an area that provides good access to the unit. Servicing may require the removal of jacket panels. Allow the minimum clearances between adjacent construction and the boiler as listed in Table 1.

Service clearances are not mandatory, but are recommended to ensure ease of service should it be required.

Table 1 – Clearances

Top Back Left Side Right Side Front

Clearance to Combustibles

in

mm

6

153

6

153

6

153

6

153

6

153

Service Clearance

in

mm

24

610

24

610

6

152

6

152

36

914

COMBUSTION AIR & VENTILATION
This boiler must be supplied with combustion air in accordance with Section 9.3, Air for Combustion & Ventilation, of the latest revision of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and all applicable local building codes. Canadian installations must comply with CSA B149.1 or .2 Installation Code for Gas Burning Appliances and Equipment, or applicable provisions of the local building codes. Failure to provide adequate combustion air for this boiler can
result in excessive levels of carbon monoxide
which can result in severe personal injury or death!

Flue

6

153

2. An optimum site will be level, central to the piping system, close to a chimney or outside wall and have

To operate properly and safely this boiler requires a continuous supply of air for combustion. NEVER store objects on or around the boiler!

adequate fresh air for combustion. Ensure that the unit is level from front to back and from side to side. Use metal shims if leveling is required. Electrical and electronic components must be protected from exposure to water during operation and maintenance. DO NOT install this boiler in a location that would
subject any of the gas ignition and other electronic components to direct contact with water or excessive

Combustion air contaminated with fluorocarbons or other halogenated compounds such as cleaning solvents and refrigerants will result in the formation of acids in the
combustion chamber. These acids will cause premature failure of the boiler voiding the warranty!

moisture during operation or servicing.
3. Ensure that the floor is structurally sound and will support the weight of the boiler.

If the boiler is operated while the building is

under construction it must be protected from

wood, concrete, sheet rock and other types

of dust. Failure to properly protect the unit

from construction dust will damage the unit

voiding the warranty!

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Cast Iron Condensing Boilers ­ Installation Manual

Buildings will require the installation of a fresh air duct or other means of providing make-up air if the intake air option isn’t used. Any building utilizing other gas burning appliances, a fireplace, wood stove or any type of exhaust fan must be checked for adequate
combustion air when all of these devices are in
operation at one time. Sizing of an outside air duct must be done to meet the requirements of all such devices.
Never operate the KN in an environment subjected to a negative pressure. Failure to comply with this warning can result in excessive levels of carbon monoxide causing severe personal injury or death!
All Air From Inside The Building
If the boiler is to be located in a confined space the minimum clearances listed in Table 1 must be maintained between it and any combustible
construction. When installed in a confined space without the intake air option two permanent openings communicating with an additional room(s) are required. The combined volume of these spaces must have sufficient volume to meet the criteria for an unconfined space. The total air requirements of all gas utilization equipment, fireplaces, wood stoves or any type of exhaust fan must be considered when making this determination. Each opening must have a minimum free area of 1 in2/1000 Btu/hr, 2200 mm2/kW based on the
total input rating of ALL gas utilization equipment in the confined area. Each opening must be no less than 100 in2, 64,516 mm2 in size. 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.
All Air From Outside The Building
When installed in a confined space without the intake air option two permanent openings communicating directly with, or by ducts to, the outdoors or spaces that freely 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 minimum free area of 1in2/ 4000 Btu/hr, 550 mm2/kW of the total input rating of all of the equipment in the enclosure.

Where communicating with the outdoors through horizontal ducts, each opening shall have a minimum free area of 1 in2/2000 Btu/hr, 1100 mm2/kW of the total
input rating of all of the equipment in the enclosure.

When ducts are used, they must have the same cross-
sectional area as the free area of the opening to which they connect.

Table 2 – Make-up Air Duct Sizing

Input (MBH)
600 1000 1600 2000 2600 3000 4000

Required Cross Sectional Duct Area

1/4 in, 6.4 mm Wire Screen

Metal Louvers

Wooden Louvers

in2 150 250 400 500 650 750 1000

cm2 967 1612 2580 3224 4194 4836 6452

in2 200 334 533 668 894 1002 1334

cm2 1292 2154 3439 4308 5595 6462 8592

in2 600 1000 1600 2000 2600 3000 4000

cm2 3869 6448 10,322 12,896 16,772 19,344 25,808

When calculating the free area necessary to meet the make-up air requirements of the enclosure, consideration must be given to the blockage effects of louvers, grills and screens.

Screens must have a minimum mesh size of 1/4 in,
6.4 mm. If the free area through a louver or grill is not known ducts should be sized per Table 2.

Direct Intake Air Option – General
This configuration provides combustion air directly to the boiler’s air intake using a dedicated pipe when using the direct vent option. Combustion air can be drawn in horizontally through an outside wall or vertically through the roof, see Figures 2, 3, 4 & 5. It must be sized per Table 3.

Single wall galvanized smoke pipe, single wall aluminum pipe, flexible aluminum pipe, PVC or CPVC pipe can be used for the intake air pipe.

Table 3 – Intake Air Pipe Sizing

Model Size
6 10 16 20 26 30 40

Pipe Diameter

in

mm

6

152

6

152

8

203

8

203

8

203

8

203

12

305

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Cast Iron Condensing Boilers ­ Installation Manual

All joints in metal intake air systems must be secured using corrosion resistant fasteners and sealed using a suitable Silicone caulk. If PVC or CPVC is used, the joints must be cleaned with a suitable solvent and connected using a solvent based PVC cement. The intake air system MUST be supported by the building structure not the boiler.
Direct Intake Air Option – Vertical The maximum equivalent length for the vertical intake air pipe is 120 ft, 36.6 m., 100 ft, 30.5 m. (KN-40). Each 90° mitered elbow and the intake air cap are equal to 10 ft, 3.3 m of straight pipe. If 90° long sweep elbows are installed use the manufacturers recommended equivalent length.
A listed, nonrestrictive intake air cap must be used. The intake air cap must terminate as shown in Figure 4. The penetration point in the roof must be properly flashed and sealed.
Direct Intake Air Option – Horizontal The maximum equivalent length for the horizontal intake air pipe is 120 ft, 36.6 m., 100 ft, 30.5 m. (KN-40). Each 90° mitered elbow and the intake air terminal are equal to 10 ft, 3.3 m of straight pipe. If 90° long sweep elbows are installed use the manufacturers recommended equivalent length.

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 the vent shall not terminate: 1) over public walkways; or 2) near soffit vents or crawl spaces or other areas where condensate or vapor could create a nuisance or hazard or cause
property damage; or 3)where condensate vapor could cause damage or could be detrimental to the operation of regulators, relief valves, or other equipment.
VENT SYSTEM OPTIONS
The KN may be vented the following ways: 1) Direct Vent (individual venting only) (page 6 & 7) –
Positive Pressure, Category IV uses a stainless steel vent system certified to UL 1738 for installations in the United States, and a stainless steel vent system certified to ULC S636 for installations in Canada. Combustion air is piped from the outdoors to the blower inlet.

Horizontal runs that exceed 5 ft, 1.5 m must be supported at 3 ft, 0.98 m intervals with overhead hangers. The intake air terminal must terminate as shown in Figures 2, 3 or 5.

2. Side Wall Vent (individual venting only) (page 13) – Positive Pressure, Category IV uses a stainless steel vent system certified to UL 1738 for installations in the

GENERAL VENTING GUIDELINES

United States, and a stainless steel vent system certified to ULC S636 for installations in Canada. Combustion air

is obtained from the space in which the unit is installed.

The vent installation must be in accordance with

Part 7, Venting of Equipment, of the National Fuel

To ensure proper operation, boilers that are

Gas Code, ANSI Z223.1/NFPA 54-latest revision

sidewall vented and use room air must not

or applicable provisions of the local building

be fired less than 10% input.

codes. Canadian installations must comply with

CSA B149.1 or .2 Installation Code. See Figure 3) Vertical Vent (individual venting only) (page 13)

A for added clarity. Improper venting can result

– Positive Pressure, Category IV uses a stainless steel

in excessive levels of carbon monoxide which

vent system certified to UL 1738 for installations in the

can result in severe personal injury or death!

United States, and a stainless steel vent system certified

to ULC S636 for installations in Canada. Combustion air

All vent systems must be fully supported by the building

is obtained from the space in which the unit is installed.

structure and not by the boiler. A minimum 12″ vent length

is required from the vent outlet adapter to center of the 4) Vertical Vent (individual venting only) (page 14)

first vent fitting. Appropriate thimbles and fire-stops must

– Negative Pressure, Category II uses stainless steel

be used where required.

vent system certified to UL 1738 for installations in the

United States, and a stainless steel vent system certified

Improper installation of common positive

to ULC S636 for installation in Canada. Combustion air

pressure vent systems can result in excessive

is obtained from the space in which the unit is installed.

levels of carbon monoxide which can cause

severe personal injury or death!

5. Common Vent (page 15) – Negative Pressure,

Category II uses a stainless steel vent system

Boiler shall not be connected to a chimney

certified to UL 1738 for installations in the United

flue serving a separate appliance, designed

States, and a stainless steel vent system certified to

to burn solid fuel.

ULC S636 for installations in Canada.

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Cast Iron Condensing Boilers ­ Installation Manual

Use (Table 4) for the maximum Category (IV) equivalent vent length and the equivalent length per fitting. Table 4 – “Category IV Equivalent Length per Fitting” chart is meant as a guideline for preliminary sizing. If vent length approaches 75% of maximum length listed, an engineered vent system calculation must be performed. Consult factory.

Abnormal wind patterns may effect overall performance.

Table 4 – Category IV Maximum Equivalent Vent Length & Equivalent Length per Fitting

Model/Outlet Diameter
Maximum Equivalent Length (Catagory IV) Standard Tee

KN6 KN10* KN16 K 4″ 4″ 5″ 6″
120′ 80′ 120′ 120′
1.25 20 ft 20 ft 25 ft 30 ft

Boot Tee Cap – Low Res (UL)

0.65 10 ft 10 ft 15 ft 15 ft 0.50 10 ft 10 ft 10 ft 15 ft

45° w/Bird Screen Elbow – 90° Elbow – 45°
Model/Outlet Diameter
Maximum Equivalent Length (Catagory IV) Standard Tee Boot Tee Cap – Low Res (UL) 45° w/Bird Screen Elbow – 90°

0.40 10 ft 10 ft 10 ft 10 ft 0.38 10 ft 10 ft 10 ft 10 ft 0.15 5 ft 5 ft 5 ft 5 ft
KN20 KN26 KN30 KN40 K* 6″ 8″ 8″ 10″
120′ 120′ 120′ 100′
1.25 30 ft 35 ft 35 ft 40 ft 0.65 15 ft 15 ft 15 ft 20 ft 0.50 15 ft 15 ft 15 ft 15 ft 0.40 10 ft 10 ft 10 ft 15 ft 0.38 10 ft 10 ft 10 ft 15 ft

Elbow – 45°

0.15 5 ft 5 ft 5 ft 7 ft

*Equivalent lengths based on K factors and (5X) pipe diameters straight length between fittings.

**KN-10 – A maximum equivalent length of 80 ft., 19.7 m utilizing 4″ vent diameter and 120 ft. 36.6 m utilizing 5″ vent diameter.

DIRECT VENT
POSITIVE PRESSURE, CATEGORY IV
In this configuration the boiler blower is used to push the flue products to the outdoors while drawing combustion air from the outdoors. The INTAKE AIR OPTION instructions under the COMBUSTION AIR & VENTILATION SECTION must be followed!
Horizontal Direct Vent Systems – Figures 2 & 3 The vent materials used in positive pressure vent systems must be certified to UL 1738 for installations in the United States, ULC S636 for installations in Canada.
To maximize the performance of single wall sheet metal vent systems locate 90° elbows as far from the boiler as possible and from one another. For best results, horizontal vent systems should be as short and straight as possible.
The vent system must be both gas and water tight. All seams and joints in metal pipes must be joined and sealed in accordance with the vent system manufacturer’s instructions.
When horizontal vent runs exceed 5 ft, 1.5m they must be supported at 3 ft, 0.98 m intervals with overhead hangers. If any part of a single wall metal vent system passes through an unheated space it must be insulated with insulation rated for 400°F, 212°C.
Horizontal vent systems shall terminate at least 4 ft, 1.3 m below, 4 ft, 1.3 m horizontally from or 1 ft, 0.23 m above any door, window or gravity air inlet into any building. It must not terminate less 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.

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Cast Iron Condensing Boilers ­ Installation Manual

Avoid terminal locations likely to be affected by winds, snowdrifts, people and pets. Protect building materials and vegetation from degradation caused by the flue gases.
When running horizontal combustion air and venting for single or multiple units, exhaust and combustion air terminals must be installed on the same plane (outside wall) in order to prevent pressure differences due to prevailing winds. In cold climates, double-wall or insulated inlet pipe recommended to prevent condensation.
Vertical Direct Vent Systems – see Figure 4 The vent materials used in positive pressure vent systems must be certified to UL 1738 for installations in the United States, ULC S636 for installations in Canada.
If any part of a single wall metal vent system passes through an unheated space it must be insulated 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 flashed and sealed.
The vent system must be gas tight. All seams and joints in metal pipes must be joined and sealed in accordance with the vent system manufacturer’s instructions.
Combination Direct Vent Systems – see Figure 5 The boiler can be vented vertically with the intake air piped horizontally through an outside wall. Follow the instructions in the INTAKE AIR OPTION – HORIZONTAL GUIDELINES on page 5. Also follow the general instructions in the COMBUSTION AIR & VENTILATION and GENERAL VENTING GUIDELINES sections.

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Cast Iron Condensing Boilers ­ Installation Manual

Table X- Approved Stainless Steel Vent Manufacturers (CAT II/IV)

Make

Model

DuraVent

FasNSeal Vent

M&G DuraVent

DuraSeal Vent

Heatfab

Saf-T Vent

Metal-Fab

CORR/GUARD

Security Chimneys

Secure Seal

Schebler Chimney Systems e Vent

VAN-PACKER

CS

Z-Flex

Z-Vent

Jeremias

DWGV/SWGV

ICC

VIC

Table Y- Approved Intake/Exhaust Terminations (CAT IV – Sidewall/Horizontal Direct Vent)

Exhaust Termination
Hood

Exhaust 90 deg

Exhaust Tee

Exhaust 45 deg

Exhaust Straight

*with bird screen
The ATH KN-Series 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. Use only listed vent manufacturers (Table X), terminations (Table Y), and transition adapters (Table Z). The chimney systems manufacturer’s installation instructions must be followed.
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Cast Iron Condensing Boilers ­ Installation Manual

Table Z – Approved Manufacturers Stainless Steel Boiler Transition Adapters (CAT II/IV)

Model Size
6
10
16 20 26 30 40

DuraVent

Boiler Adapter*

Flue

810009369

810013226

810005652

FasNSeal

810005651

810013230

M&G DuraVent (DuraSeal)

Transition Adapter

Flue

DS4FFNSAU DSD4FFNSAUK

DS5FFNSAU DSD5FFNSAUK

DS6FFNSAU

DS

DSD6FFNSAUK

DSD

DS8FFNSAU DSD8FFNSAUK

DS10FFNSAU DSD10FFNSAUK

ICC

Transition Adapter
HM-4AC HM-4SDA
HM-5AC HM-5SDA
HM-6AC HM-6DSDA
HM-8AC HM-8DSDA
HM-10AC HM-10DSDA

Flue
VIC-SW VIC-DW

Metal-Fab

Transition Adapter
No Adapter Needed
No Adapter Needed
6FCSLXL

Flue
Corr/Guard

8FCSLCA

10FCSPKA2

Model Size
6
10
16 20 26 30 40

Heatfab (Saf-T Vent)

Transition Adapter

Flue

9401MAD

9501MAD 9601MAD 9801MAD

EZ/GC Cl Plus

91001MAD

Security Chimneys (Secure Seal)

Transition Adapter

Flue

SS4FFNSAU SSD4FFNSAUK

SS5FFNSAU SSD5FFNSAUK

SS6FFNSAU

SS

SSD6FFNSAUK

SSD

SS8FFNSAU SSD8FFNSAUK

SS10FFNSAU SSD10FFNSAUK

Jeremias

Transition Adapter

Flue

SWGV4-RCIS

SWGV5-RCIS SWGV6-RCIS

DWGV SWGV

SWGV8-RCIS

SWGV10-RCIS

Model Size
6

VAN-PACKER

Transition Adapter

Flue

C04VLSL/M

10

C05VLSL/M

16 20

C06VLSL/M

CS

26 30

C08VLSL/M

40

C10VLSL/M

*Factory Installed

Z-Flex

Transition Adapter

Flue

2SVSAFNS04

2SVSAFNS05

2SVSAFNS06

Z-Flex

2SVSAFNS08

2SVSAFNS10

Schebler Chimney Systems (e-Vent)

Transition Adapter

Flue

ESW-UNAK-04R EVD-UNAK-04R

ESW-UNAK-05R EVD-UNAK-05R

ESW-UNAK-06R

ESW

EVD-UNAK-06R

EVD

ESW-UNAK-08R EVD-UNAK-08R

ESW-UNAK-10R EVD-UNAK-10R

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Cast Iron Condensing Boilers ­ Installation Manual

Figure 1 – KN-Series Multiple Boiler Common Venting

FLUE VENT

DOUBLE ACTING BAROMETRIC DAMPER
THERMAL SPILL SWITCH

“B”
ALL CONNECTIONS TO BE “T-WYE”
“D”

BOILER #4 (IF REQUIRED)

BOILER #3 (IF REQUIRED)

BOILER #2 (IF REQUIRED)

MULTIPLE BOILER NEGATIVE DRAFT VENTING INSTALLATION

BOILER #1

“C”

“F”

AIOM-051_G

VERTICAL CHIMNEY VENTING – VERTICAL VE MULTIPLE BOILER INSTALLATIONS
IT IS RECOMMENDED THAT THE BOILERS NE WHEN THE HORIZONTAL DISTANCE EXCEED
WHEN SIZED FOR A (CAT II) CONFIGURATIO REQUIRED IN EACH BOILER’S RISER WHEN A DAMPER MUST BE INSTALLED AS ILLUSTRA ACCEPTED ENGINEERING PRACTICES AND D BAROMETRIC DAMPERS, THE BAROMETRIC CODES, INSTALL A THERMAL SPILL SWITCH
1. CONNECT EACH BOILER RISER TO THE CO ONLY
2. INSTALL AN APPROVED VENT CAP AT EAC
3. DIMENSIONS: B = BREECHING LENGTH C = CHIMNEY HEIGHT D = BREECHING DIAMETER F = RISER DIAMETER (NO SMALLER THAN THE DIMENSION GIV
4. MULTI-STORY, COMMON VENTING SYSTE CODE, ANSI Z223.1/NFPA 54 AND/OR THE (CURRENT EDITIONS), LOCAL CODES AND THE CHIMNEY AND BREECHING USING GE (CONSULT FACTORY FOR VERTICAL HEIG

VERTICAL CHIMNEY VENTING – Vertical venting multiple boiler installations:
It is recommended that the boiler nearest the vertical chimney be fired first when the horizontal distance exceeds 50% of the vertical distance.
When sized for a (CAT II) configuration, a negative pressure of 0.02 to 0.10 inches WC is required in each boiler’s riser when all boilers are operating at full input. A barometric damper must be installed as illustrated. [Exception: if the vent system is designed using accepted engineering practices, and the design calculations prove there is no need for barometric dampers, the barometric dampers may be omitted.] When required by applicable codes, install a thermal spill switch on each barometric damper.

1. Connect each boiler riser to the common vent with a Y connection only.
2. Install an approved vent cap at each vent termination.
3. Dimensions: B = breeching length C = chimney height D = breeching diameter F = riser diameter
(No smaller than the dimension given in Table 4)
4. Multi-story, common venting systems shall be in accordance with the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/ or the CSA B149.1, Natural Gas and Propane Installation Code (Current Editions), local codes and vent manufacturer’s installation instructions. Size the chimney and breeching using generally accepted engineering practices. (Consult factory for vertical heights beyond 60 ft.)

10

Cast Iron Condensing Boilers ­ Installation Manual

Figure 2 – Horizontal Air Intake and Venting for a Single Direct Vent System

PITCH PIPE DOWN TOWARDS BOILER
1/4 IN/FT [20 mm/m]

PITCH PIPE DOWN TOWARDS TERMINAL
CAP 1/4 IN/FT [20 mm/m]

10 FT [3.1 m] MINIMUM
TO ADJACENT BUILDING
REFER TO TABLE “Y” FOR APPROVED VENT TERMINATION AND DIMENSIONAL DATA

EXHAUST
“Y” MINIMUM BETWEEN TERMINALS
COMBUSTION AIR 1.5 FT [0.5 m] MINIMUM DISTANCE FROM
INTAKE TO MAXIMUM SNOW LINE.

NOTES:
1. DIMENSIONS ARE IN INCHES (IN), FEET (FT), MILIMETERS [mm] OR METERS [m] AS SHOWN.

WARNING: When running horizontal combustion air and venting for single or multiple units, exhaust and combustion air terminals must be installed on the same plane (outside wall) in order to prevent pressure differences due to prevailing winds. In cold climates, double-wall or insulated inlet pipe recommended to prevent condensation.

“X” MINIMUM BETWEEN TERMINALS @ CENTER LINE

Figure 3 – Horizontal Air Intake and Venting for Multiple Direct Vent Systems
EXHAUST TERMINAL BANK

COMBUSTION AIR INTAKE TERMINAL
BANK

1.5 FT [0.5 m] MINIMUM DISTANCE FROM
INTAKE TO MAXIMUM SNOW LINE.

2 IN [50.8 mm] MINIMUM BETWEEN TERMINALS

NOTES:

AIOM-065_B

1. DIMENSIONS ARE IN INCHES (IN), FEET (FT), MILIMETERS [mm] OR METERS [m] AS SHOWN.

11

Cast Iron Condensing Boilers ­ Installation Manual Figure 4 – Vertical Air Intake and Venting for Direct Vent System

AIOM-003_C

Figure 5 – Combination Direct Vent Systems

MAXIMUM

MAXIMUM
12

COMBUSTION AIR

EXHAUST

Cast Iron Condensing Boilers ­ Installation Manual

SIDE WALL VENT POSITIVE PRESSURE, CATEGORY IV
In this configuration the boiler blower is used to push the flue products horizontally to the outdoors, see Figure 6.
To ensure proper operation, boilers that are vented sidewall and use room air must not fire less than 10% input.

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 HORIZONTAL DIRECT VENT SYSTEMS section must also be followed.

Figure 6 – Side Wall Venting

1/4 IN/FT [20 mm/m]

1.5 FT [.5 m]

(IN)

(FT)

[mm] [m]

VERTICAL VENT (Recommended)
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 followed.

Figure 7 – Vertical Positive Pressure Venting
10 FT [3.1 m] MINIMUM TO WALL
OR ADJOINING BUILDING

APPROVED NORESTRICTIVE
TERMINAL
ROOF FLASHING

1.5 FT [.5 m] MIN FOR PIPE DIAMETER 12 IN [30 cm] AND 2.0 FT [.6 m] MIN FOR PIPE DIAMETER > 12 IN [30 cm] MAXIMUM SNOW LINE

CLEARANCES PER VENT MANUFACTURER’S INSTRUCTIONS

AIOM-006_D

EXHAUST
UL CERTIFIED VENT SYSTEM NOTES: 1. DIMENSIONS ARE IN INCHES (IN), FEET (FT), MILIMETERS [mm] OR METERS [m] AS SHOWN.

13

Cast Iron Condensing Boilers ­ Installation Manual

VERTICAL VENT (Optional)
NEGATIVE PRESSURE – CATEGORY II
The KN is listed as a Category II appliance when vented vertically into a listed metal AL294C S.S. chimney system, Figure 8. The chimney system must provide a negative pressure of 0.02 to 0.10 in, 0.51 to 2.5 mm WC at the boiler flue collar with the unit running.

When using a listed metal chimney system the chimney system 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 lists the mimimum riser sizes required for the KN boiler – Category II.

If an appliance using any type of a mechanical draft system operating under positive pressure is connected to a chimney flue, never connect any other appliances to this flue. Doing so can result in excessive levels of carbon monoxide which can cause
severe personal injury or death!

Table 5 – Minimum Riser Connection, Negative Pressure – Category II

Model Size
6 10 16 20 26 30 40

Diameter

in

mm

8

203

8

203

10

254

10

254

12

305

12

305

14

356

Vent system must be sized per an engineered system

Vent Connections
Locate the boiler as close to the chimney system as
possible. Use the shortest, straightest vent connector possible for the installation. If horizontal runs exceed 5 ft, 1.5 m they must be supported at 3 ft, 0.9 m intervals with overhead hangers. Use the appropriate vent connector of the same diameter as the flue collar to connect the boiler to a listed metal chimney system. Follow the chimney system manufacturer’s instructions 14 for proper assembly.

The vent system should be sloped up toward the chimney at a minimum rate of 1/4 in/ft, 2 cm/m.
Always provide a minimum clearance of 6 in, 152 mm between single wall vent pipe and any combustible materials.
Failure to maintain minimum clearances between vent connectors and any combustible material can result in a fire causing extensive property damage, severe personal injury or death!

Exit cones are favorable when used
to increase the velocity of the flue
gas exiting the stack and, may also help, in cold climates, to reduce ice build-up. Exit cone terminations must be supplied by others, installed per manufacturer’s instructions, and meet local and federal code.

generic exit cone

Figure 8 – Vertical Venting with a Metal Chimney System

2 FT [.6 m] 10 FT [3.1 m]

Note: 1) All building
structural
modifications by others. 2) Firestopping per local building codes.

1. [m]

(IN)

(FT)

[mm]

Cast Iron Condensing Boilers ­ Installation Manual

EXISTING COMMON VENT SYSTEMS
If an existing boiler is removed from a common venting system, the common venting system may then be too large for the proper venting of the remaining appliances connected to it. At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.
Au moment du retrait d’une chaudière existante, les mesures suivantes doivent être prises pour chaque appareil toujours raccordé au système d’évacuation commun et qui fonctionne alors que d’autres appareils toujours raccordés au système d’évacuation ne fonctionnent pas: système d’évacuation

Dans la mesure du possible, fermer toutes les portes et les fenêtres du bâtiment et toutes les portes entre 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 fonctionner les ventilateurs d’été. Fermer les registres des cheminées.
d) Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so appliance will operate continuously.

a) Seal any unused openings in the common venting system.
Sceller toutes les ouvertures non utilisées du système d’évacuation.
b) Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition.

Mettre l’appareil inspecté en marche. Suivre les instructions d’allumage. Régler le thermostat de façon que l’appareil fonctionne de façon continue.
e) After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas-burning appliance to their previous condition of use.

Inspecter de façon visuelle le système d’évacu-ation pour déterminer la grosser et l’inclinaison horizontale qui conviennent et s’assurer que le système est exempt d’obstruction, d’étranglement de fruite, de corrosion et autres défaillances qui
pourraient présenter des risques.

Une fois qu’il a été d éterminé, selon la métode indiquée ci-dessus, que chaque appareil raccordé au système d’évacuation est mis à l’air libre de façor adéquate. Remettre les portes et les fenêtres, les ventilateurs, les registres de cheminées et les appareils au gaz à leur position originale.

c) Insofar as is practical, close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhaust, so they will operate at maximum speed. Do not operate a summer exhaust fan for a boiler installation. Close fireplace dampers.

f) Any improper operation of the common venting system should be corrected so the installation
conforms with the National Fuel Gas Code, ANSI Z223.1/NFPA 54. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Appendix F in the National Fuel Gas Code, ANSI Z223.1/ NFPA 54 and or CSA B149 Installation Codes.

Tout mauvais fonctionnement du systéme d’évacution commun devrait étré corrigé de façor que l’installation soit conforme au National Fuel Gas Code, ANSI Z223.1/NFPA 54 et (ou) aux codes d’installation CSA-B149. Si la grosseur d’une section du système d’ évacuation doit étré modifiée, le système devrait étré modifié pour respecter les valeurs minimales des tableaux pertinents de l’appendice F du National Fuel Gas Code, ANSI Z223.1/NFPA 54 et (ou) des codes d’installation CSA-B149.
15

Cast Iron Condensing Boilers ­ Installation Manual

Figure A – Direct Vent Terminal Clearances

Canadian Installations¹

US Installations²

A =

Clearance above grade, veranda, porch, deck, or balcony

12 in (30 cm)

12 in (30 cm)

B =

Clearance to window or door that may be opened

6 in (15 cm) for appliances < 10,000 Btuh (3 kW); 12 in (30 cm) for appliances

10,000 Btuh (3 kW) and < 100,000 Btuh (30 kW); 36 in (91 cm) for appliances 100,000 Btuh (30 kW)

6 in (15 cm) for appliances < 10,000 Btuh (3 kW); 9 in (23 cm) for appliances

10,000 Btuh (3 kW) and < 50,000 Btuh (15 kW); 12 in (30 cm) for appliances > 50,000 Btuh (15 kW)

C =

Clearance to permanently closed window

Vertical clearance to ventilated soffit

D =

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

Per local installation codes

F = Clearance to outside corner

G = Clearance to inside corner
Clearance to each side of center line H = extended above meter / regulator
assembly

3 ft (91 cm) within a height of 15 ft (4.6m)

I =

Clearance to service regulator vent outlet

3 ft (91 cm)

Clearance to nonmechanical air supply J = inlet to building or the combustion air
inlet to any other appliance

6 in (15 cm) for appliances < 10,000 Btuh (3kW); 12 in (30 cm) for appliances

10,000 Btuh (3 kW) and < 100,000 Btuh (30 kW); 36 in (91 cm) for appliances 100,000 Btuh (30 kW)

6 in (15 cm) for appliances < 10,000 Btuh (3kW); 9 in (23 cm) for appliances > 10,000 Btuh (3 kW) and < 50,000 Btuh (15 kW); 12 in (30 cm) for appliances > 50,000 Btuh (15 kW)

16

Cast Iron Condensing Boilers ­ Installation Manual

Figure A – Direct Vent Terminal Clearances – Concluded

K =

Clearance to a mechanical air supply inlet

Clearance above paved sidewalk

L =

or paved driveway located on

public property

M =

Clearance under veranda, porch, deck, or balcony

6 ft (1.83 m) 7 ft (2.13 m) 12 in (30 cm)

3 ft (91 cm) above if within 10 ft (3 m) horizontally
Vents for Category II and IV appliances cannot be located above public walkways or other areas where condensate or vapor can cause a nuisance or hazard
Per local installation codes

A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family

dwellings and serves both dwellings.

Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor.

NOTES:

In accordance with the current CSA B149.1, Natural Gas and Propane Installation Code

In accordance with the current ANSI Z223.1/NFPA 54, National Fuel Gas Code

If locally adopted installation codes specify clearances different than those illustrated, then the most stringent clearances must prevail.

Figure A – Other Than Direct Vent Terminal Clearances

Canadian Installations¹ US Installations²

A =

Clearance above grade, veranda, porch, deck, or balcony

12 in (30 cm)

12 in (30 cm)

B =

Clearance to window or door that may be opened

6 in (15 cm) for appliances < 10,000 Btuh (3 kW); 12 in (30 cm) for appliances

10,000 Btuh (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

Vertical clearance to ventilated soffit

D =

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

Per local installation codes

G = Clearance to inside corner
Clearance to each side of center line H = extended above meter/regulator
assembly

3 ft (91 cm) within a height of 15 ft (4.6m)

I =

Clearance to service regulator vent outlet

3 ft (91 cm)

6 in (15 cm) for appliances < 10,000

4 ft (1.2 m) below or to side of opening;

Clearance to nonmechanical air supply Btuh (3kW); 12 in (30 cm) for appliances 1 ft (300 mm) above opening

J = inlet to building or the combustion air

10,000 Btuh (3 kW) and < 100,000

inlet to any other appliance

Btuh (30 kW); 36 in (91 cm) for

appliances > 100,000 Btuh (30 kW)

17

Cast Iron Condensing Boilers ­ Installation Manual

Figure A – Other Than Direct Vent Terminal Clearances – Concluded

K =

Clearance to a mechanical air supply inlet

Clearance above paved sidewalk or L = paved driveway located on public
property

6 ft (1.83 m) 7 ft (2.13 m)

M =

Clearance under veranda, porch, deck, or balcony

12 in (30 cm)

3 ft (91 cm) above if within 10 ft (3 m) horizontally
Vents for Category II and IV appliances cannot be located above public walkways or other areas where condensate or vapor can cause a nuisance or hazard
Per local installation codes

A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings

and serves both dwellings.

Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor.

NOTES:

In accordance with the current CSA B149.1, Natural Gas and Propane Installation Code

In accordance with the current ANSI Z223.1/NFPA 54, National Fuel Gas Code

If locally adopted installation codes specify clearances different than those illustrated, then the most stringent clearances must prevail.

18

Cast Iron Condensing Boilers ­ Installation Manual

OUTDOOR VENTING
When installed outdoors the KN must be fitted with 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 shrubbery might cause a downdraft. The unit(s) shouild be located at least 3 ft, 1 m from structures. Outdoor installations are not recommended in areas where the danger of snow blockage exists.
Do not place the boiler in a location that would subject it to runoff from adjacent buildings or damage may occur voiding the warranty!
The boiler and system must be filled with a glycol mixture not to exceed 50% by volume. All water piping exposed to low temperatures must be insulated.

Figure 8B – Multiple Outdoor Units

3 FT [1 m]

2 FT [0.61 m]

Figure 8A – Outdoor Venting

AIOM-100_B

AIOM-101_B
NOTES:
1. DIMENSIONS ARE IN INCHES (IN), FEET (FT), MILIMETERS [mm] OR METERS [m] AS SHOWN.
The KN-Series Boiler is certified for outside installations in temperate climate not subject to freezing temperatures.
1. The condensate traps located under the secondary heat exchanger and the vent pipe must be wrapped with heat tape to ensure the traps never drop below 32°F.
2. The vent pipe must be insulated to prevent freezing of condensate in the pipe.
3. The boiler and system must be filled with a propylene glycol/water antifreeze mixture not to exceed 50% glycol by volume.
4. All water piping exposed to low temperatures must be insulated.
5. A continuous flow of water through the unit MUST be maintained! The pump responsible for flow through the boiler/water heater must run continuously!
19

Cast Iron Condensing Boilers ­ Installation Manual

GENERAL PIPING REQUIREMENTS
Improper piping of this boiler will void the manufacturer’s warranty and can cause boiler failure resulting in flooding and extensive property damage!
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 servicing be necessary.
Relief Valve Pipe the discharge of the pressure relief valve as shown in Figure 9. Mount on rear section or vertically on supply nipple.
Never install any type of valve between the boiler and the relief valve or an explosion causing extensive property damage, severe personal injury or death may occur!
Flow Sensor The factory mounted SIKA flow sensor, as shown in Figure 9, is wired to prevent the boiler from firing unless there’s adequate water flow, (Table 6), through the unit.
The SIKA flow sensor sends information to the HeatNet control and displays the water flow information in (gpm). The minimum flow settings are fully adjustable. The boiler will not operate if the (gpm) falls below the minimum value. If the system is using Glycol the % of glycol mixture must be entered. The SIKA Flow sensor is limited to 194°F, 90°C water temperature, 145 psi operating pressure and a 50% glycol mixture. If the return water temperature rises above 194°F, 90°C the boiler will shut down. For applications outside these requirements, please consult Manufacturer. Reference the HeatNet IOM for menu instructions.

In order to maintain boiler capacity, increase flow rates approximately (10%) and pump head (25%) for mixtures up to 50% glycol.

Table 6 – Temperature Rise Table

Model Size
6 10 16 20 26 30 40

Water Flow Rates

(GPM)

100%-Input

10%-Input

Min.*

Max.*

Min.

10.8

54.0

10.8

18.0

90.0

18.0

28.8

144.1

23.8

36.0

180.0

33.2

46.8

234.1

41.5

54.0

270.1

48.4

70.8

354.1

63.9

*Min/Max flow correspond to a (20°F/100°F) t at full

input. Verify system pipe sizing allows for flow velocity

requirements.

Use the following equation to determine the boiler derate capacity when adjustments aren’t made. (2012 ASHRAE Systems Handbook)

qw = 500Q(p/pw)CpT

Where
qw = Total heat transfer rate, BTU/h
Q = flow rate, gpm p = fluid density, lb/ft³ pw = density of water at 60°F, lb/ft³ Cp = specific heat of fluid, Btu/lb °F T = temperature difference, °F

Figure 9

LOW WATER CUT OFF
AIR VENT

HI-LIMIT
TEMP/PRESSURE GAUGE

PRESSURE RELIEF VALVE

DISCHARGE PIPE SIZE TO EQUAL VALVE OUTLET DO NOT RESTRICT FLOW

Air Vent
The factory mounted air vent, as shown in Figure 9, is installed to automatically purge unwanted air from the boiler allowing the system to run more effectively.

SUPPLY OUTLET FLOW SENSOR

Please note that after installing in a new system or retrofitting an old, close the Boiler isolation valve installed upstream of the Air Vent prior to filling the system with water. Once the system has been properly filled open the Air Vent isolation valve for automatic operation. If this is not done, it is entirely possible that the internal float mechanism will become clogged open, causing the air vent to leak.

RETURN INLET FLUE OUTLET

BOILER

Prevent supply/return nipple from turning

CONDENSATE DRAIN ASSY.

20

during attachment to system piping.

AIOM-008_F
DISCHARGE SO AS TO AVOID EXPOSURE OF PERSONS TO HOT LIQUID OR VAPOR AND ALLOW COMPLETE DRAINAGE OF RELIEF VALVE AND PIPING

Cast Iron Condensing Boilers ­ Installation Manual

HEATING SYSTEM PIPING
General Piping Requirements All heating system piping must be installed by a qualified technician in accordance with the latest revision of the ANSI/ASME Boiler and Pressure Vessel Code, Section IV.
Where required, the piping must comply with ANSI/ ASME CSD-1, Standard for Controls and Safety Devices for Automatically Fired Boilers.
All applicable local codes and ordinances must also be followed. A minimum clearance of 1in, 25 mm must be maintained between heating system pipes and all combustible construction. All heating system piping must be supported by suitable hangers, not the boiler. The thermal expansion of the system must be considered when supporting the system. A minimum system pressure of 20 psig, 138 kPa must be maintained at boiler operating conditions. For glycol systems, a minimum system pressure of 30 psig, 207 kPa must be maintained at boiler operating conditions.
When equipped with a boiler pressure transducer, pressure will be monitored closely for increased protection. A warning and/or alarm will be detected when conditions fall below the following parameters:
Warning (boiler water) – pressure < 18 psi Warning (boiler water/glycol mix) – pressure < 28 psi Alarm – pressure < 15 psi
Boiler Piping Connections The supply and return connections should be sized to suit the system, see Table 7.

Water Treatment This boiler was designed to operate in a closed loop heating system. System fill water must not contain more than 500 ppm of total dissolved solids 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). The PH level must be within the 6.5-11 range. Where required, 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 ensure proper protection to the boiler.
The water used for dilution of concentrated heat transfer fluids must be distilled, de-ionized, or equivalently clean as stated above. De-ionized water by itself can be aggressive torwards many metals, but is perfectly safe when used for dilution of DOWFROST, DOWTHERM or UCARTHERM as specified by the manufacturer.
FAILURE TO ENSURE PROPER WATER QUALITY CAN RESULT IN DAMAGE TO THE BOILER(S) VOIDING THE WARRANTY.
Water Meter Make-up water introduced into a closed system due to system leaks can negatively affect the long term reliability of the heating sytem resulting in abnormal boiler water quality. It is recommended that a water meter be installed in the system make-up line. If makeup is recorded, the leaks must be found and repaired.

Table 7 – Supply & Return Pipe Sizing

Model Size 6 10 16 20 26 30 40

Supply Size 3″ NPT 3″ NPT 3″ NPT 3″ NPT 4″ NPT 4″ NPT 4″ NPT

Return Size 3″ NPT 3″ NPT 3″ NPT 3″ NPT 4″ NPT 4″ NPT 4″ NPT

Pump Requirements
This boiler requires a continuous minimum water flow for proper operation. The system pump must be sized to overcome the head loss of the boiler and the heating system in order to achieve the required temperature rise. If the system contains hydronic antifreeze this must be considered when sizing the pump. The temperature rise across the boiler must never exceed 100°F, 55.6°C.

System Cleaning & Flushing: Prior to
commissioning the boiler(s), the piping/ system must be cleaned and flushed to prevent contaminants from settling back into the boiler and fouling the heat exchanger.
Isolate the boiler from the system prior to the cleaning process. Fill the system with water, add the cleaning solution and follow the solution manufacturer’s instructions. Once clean, refill the system with clean water as specified in the Water Treatment section.

Low Water Cutoff
Each KN boiler comes equipped with a factory installed low water cutoff.

Expansion Tank & Air Separator

An expansion tank or other means to control thermal

expansion must be installed in the heating system. It

is recommended the expansion tank is installed close

to the suction side of the pump. Coalescing style air

separators are strongly recommended in Variable Speed

Systems where velocities can vary and maybe too slow

for conventional type air separators. Failure to follow these

guidelines will result in poor system performance with

minimal air removal and may void the factory warranty.

21

Cast Iron Condensing Boilers ­ Installation Manual

Reverse Return Piping (RECOMMENDED)
Consideration of system thermal mass, minimum
system load & system flow must be based on the relationship between the boiler minimum output and the system’s ability to absorb the energy. Insure at least a ten (10) minute boiler run cycle at minimum system load. Systems using multiple boilers can also be installed using a reverse return system, Figure 11.
Primary/Secondary Piping
Although acceptable, the system is not as cost effective as reverse return piping. Figure 12 shows a typical primary/secondary piping system. A dedicated pump is used to maintain a constant water flow through 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 system, must be installed so the chilled medium is piped in parallel with the boiler. Appropriate valves must be used to prevent the chilled water from entering the boiler.
When a boiler is connected to a heating coil that may be exposed to refrigerated air from an air handling device, the piping system must be equipped with flowcontrol valves or some other automatic means of preventing gravity circulation of the boiler water during the cooling cycle.
It is essential that following boiler shut off, the boiler pump continue to operate for approximately (5) minutes to dissipate the heat away from the heat exchanger.

Figure 10 – Typical Single Boiler Piping (RECOMMENDED) (Circulator pump must be sized for minimum water flow rate of boiler, including system pressure drop)

WM
WM
22

Cast Iron Condensing Boilers ­ Installation Manual
Figure 11 – Typical Multiple Boiler Reverse Return Piping (RECOMMENDED) (Careful consideration as to minimum boiler and system water flow rates must be taken. Please consult our local manufactures representative for assistance.)
Motorized Valve

(IN)

(FT)

[mm] [m]

NOTE: Not all system valves may be shown. Consult local codes for additional system components which may be necessary. For HeatNet operation, a sensor is required and installed at a minimum of 12″ from primary loop tee.
Figure 12 – Typical Single Boiler Primary/Secondary Piping

(IN)

(FT)

[mm] [m]

NOTE: Not all system valves may be shown. Consult local codes for additional system components which may be necessary. For HeatNet operation, a sensor is required and installed at a minimum of 12″ from primary loop tee.
Figure 13 – Typical Multiple Boiler Primary/Secondary Piping

(IN)

(FT)

[mm] [m]

NOTE: Not all system valves may be shown. Consult local codes for additional system components which may be necessary. For HeatNet operation, a sensor is required and installed at a minimum of 12″ from primary loop tee.

WM Water Meter
23

Cast Iron Condensing Boilers ­ Installation Manual

DOMESTIC WATER SUPPLY PIPING
Proper controls must be used to prevent water supplied for domestic use from exceeding 130°F, 54°C or a scald injury will occur! When higher water temperatures are required for appliances such as a dishwasher, a mixing valve or some other tempering means must be installed. Households with small children may require
water temperatures less than 120°F, 49°C. Local codes must be complied with!
General Piping Requirements
The KN boiler can be use in combination with an indirect tank to provide hot water for domestic use. Piping and components must be suitable for use with potable water. The indirect storage tank must be equipped with a temperature and pressure relief valve that complies with ANSI Z21.22 or CAN-4.4 and CAN-4.6.

The storage tank must be located as close to the boiler as possible to prevent excessive head loss which will reduce flow.
Expansion Tank An expansion tank or other means to control thermal expansion must be installed in the water heating system if back flow prevention devices are installed.
Two typical water heating systems are shown in Figures 14 & 15.
Thermostatic Mixing Valve- Water Above 140°F, 60°C Water can be stored a temperatures above 140°F, 60°C provided that a thermostatically controlled mixing valve is used to temper the hot water 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

NOTES: 1. Locate HeatNet 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. Hot water tank should be equipped with a combination temperature and pressure relief valve. Valve shall discharge to a safe place with an air gap. Refer to local codes.
4. MA Code requires an 1/8″ hole in check valves to compensate for thermal expansion.
5. Contractor shall verify, with authority having jurisdiction, for the requirements of an acid neutralization kit.
6. A thermostatic mixing valve may be required at the outlet of the tank in order to limit the mixed water to a desirable temperature helping to prevent scalding and injury. Consult local codes.
Notice: These drawings show suggested piping configuration, valving and are diagrammatic. Check with local codes and ordinances for specific requirements.

SUPPLY 2

COLD WATER MAKE-UP 2
4
FLOW 3
FLOW 1

AIOM-012_J

4

COLD WATER MAKE-UP
FLOW CIRCULATOR RETURN

BRONZE PUMP

NOTE: Not all system valves may be shown. Consult local codes for additional system components which may be necessary.

PUMP

GATE VALVE CHECK VALVE

BACKFLOW PREVENTION DEVICE

24

TEMPERATURE & PRESURE
RELIEF VALVE

PRESURE VACUUM RELIEF THERMOMETER

RELIEF VALVE

VALVE

EXPANSION TANK

HEAT NET SENSOR

Cast Iron Condensing Boilers ­ Installation Manual

Figure 15 – Typical Multiple Boiler with Indirect Storage Tank Piping

NOTES: 1. Locate HeatNet 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 and pressure relief valve. Valve shall discharge to a safe place with an air gap. Refer to local codes.

5. MA Code requires an 1/8″ hole in check valves to compensate for thermal expansion.

6. Contractor shall verify, with authority having jurisdiction, for the requirements of an acid neutralization kit.

7. A thermostatic mixing valve may be required at the outlet of the tank in order to limit the mixed water to a desirable
temperature helping to prevent scalding and injury. Consult local codes.

Notice: These drawings show

suggested piping configuration,

valving and are diagrammatic.

3

Check with local codes

and ordinances for specific

requirements.

COLD WATER MAKE-UP
2
FLOW 5
FLOW
2

COLD WATER
MAKE-UP/FILL 5

BRONZE PUMP

4 SUPPLY

CIRCULATOR RETURN

1

FLOW FLOW

AIOM-013_J

NOTE: Not all system valves may be shown. Consult local codes for additional system components which may be necessary.

GATE VALVE CHECK VALVE

BACKFLOW PREVENTION DEVICE

TEMPERATURE & PRESURE
RELIEF VALVE

PRESURE VACUUM RELIEF THERMOMETER

RELIEF VALVE

VALVE

EXPANSION TANK

HEAT NET SENSOR

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Cast Iron Condensing Boilers ­ Installation Manual

CONDENSATE PIPING
The condensate trap provided with the boiler must be attached to the bottom pan and piped to a suitable floor drain (consult local code) or condensate 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.
Figure 16 – KN-Series Condensate Drain

HIGH TURNDOWN TRAP

STANDARD TRAP

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 supply. Failure to comply with this warning can result in extensive property damage, severe personal injury or death!
The KN comes from the factory ready to be piped to the gas supply. If for any reason the boiler is not for the type of gas available at the installation site, call your Advanced Thermal Hydronics representative to resolve the problem.

Do not size the gas supply line nominal iron pipe size based only on the boiler gas inlet connection size. The gas supply line (feed) to the boiler gas inlet connection must be designed per an engineered method and utilizing (Table 8) to ensure that the gas supply piping is sized properly. Do not neglect the pressure drop due to pipe fittings. (Table 8) should be used in conjunction with (Table 9) to ensure that the gas supply piping has the capacity to meet the demand. If more than one appliance is supplied by the same supply pipe, the piping must be sized based on the maximum possible demand.

Figure 17 depicts the proper way to connect the boiler to the gas supply piping. The manual shut-off valve MUST be installed in the supply piping. It should be installed 5 ft, 1 m above the floor where required by local codes. Provide a sediment trap at the bottom of the vertical section of the gas supply pipe upstream of the gas controls.

A ground joint union should be installed between the boiler gas controls and the supply piping. Each of these items are needed to ensure long life and ease of servicing. Always use a pipe sealant that is suitable for use with with the type of gas (NG/LP) being used.

Table 8 – Gas Pipe Capacity

Maximum pipe capacity in ft3/hr based on 0.60 specific gravity gas at a pressure of 0.5 psig or less and a 0.3″ WC pressure drop.

Nominal Iron Pipe 10
Size

Pipe length in feet 20 30 40 50 60 80 100 150
Maximum gas volume of pipe (ft3/hr)

1″ 520 350 285 245 215 195 170 150 120

11/4″ 1050 730 590 500 440 400 350 305 250

11/2″ 1600 1100 890 760 670 610 530 460 380

2″ 3050 2100 1650 1450 1270 1150 990 870 710

21/2″ 4800 3300 2700 2300 2000 1850 1600 1400 1130

3″ 8500 5900 4700 4100 3600 3250 2800 2500 2000

Note: Multiply the gas volume by 0.62 for propane flow capacity in ft3/hr. Multiply the propane flow capacity by 2500 Btu/ft3 to determine the propane Btu/hr capacity for a given pipe size and length.

Table 9 – Equivalent Pipe Length Chart

Nominal Iron Pipe
Size

Type of pipe fitting

90° Elbow

Tee1

Gas Valve2

Equivalent pipe length, (ft)

1″

2.6

5.2

0.6

11/4″

3.5

6.9

0.8

11/2″

4.0

8.0

0.9

2″

5.2

10.3

1.2

Notes: 1. For flow through branch. 2. For flow at full open.

Gas Cock2
1.5 1.9 2.3 3.0

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Cast Iron Condensing Boilers ­ Installation Manual

Figure 17 – Gas Supply Piping

CSD-1 TEST PORTS

MODULATING GAS VALVE

A lockup style regulator, supplied by others, must be installed, see Figure 17, if gas pressure exceeds (14 in WC). The regulator, when installed as shown, must be installed at a distance of at least 10 pipe diameters from the boiler main gas valve. All boilers are calibrated and factory test fired at (7 in ± 1.0) WC.
A minimum of (3 in WC) and maximum of (14 in WC) must be maintained to the inlet of the boiler gas train not to exceed a maximum of (1 in WC) drop when firing from minimum input to full load of the gas supply line and all the appliances running.
Always use a wrench on the gas valve body when making gas connections to it. Never over-tighten the piping entering the gas valve body or gas valve failure may result!
Safe lighting and other performance criteria were met with the gas manifold and control assembly provided on the boiler. All gas connections MUST be leak tested before putting the boiler into operation.
Never use an open flame to test for gas leaks. Always use an approved leak detection method. Failure to comply with this warning can cause extensive property damage, severe personal injury or death!
Gas train must be isolated when purging the gas line prior to commissioning the boiler.

Corruption of the gas train components with debris and cutting oils can reduce reliable operation which can have a negative effect on the operation & manufacturers warranty of the Dungs gas valve. The factory supplied Dungs MBC modulation gas valve, see Figure 17, incorporates an internal filter that must be inspected and changed at required intervals. Reference the Dungs MBC Installation Instructions – 264541 for detailed instructions. Combined with clean gas pipes and good plumbing practices (such as installing a drip leg), should adequately protect the MBC valve seat, regulator and internal orifices from clogging or damage. However, site conditions might warrant an additional filter. This should be installed upstream of the appliance gas regulator to the unit.

Whenever the gas supply piping is pressure tested the boiler gas controls must be protected. If the test pressure is equal to, or less than 1/2 psig, 3.5 kPa isolate the boiler
by closing its’ manual shut off valve, see Figure 17. If the test pressure is greater than, or equal to 1/2 psig, 3.5 kPa, disconnect the boiler and its individual shut-off valve.

ELECTRICAL WIRING

Electrical Power Connections

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation! Verify proper operation after servicing.

ATTENTION. Au moment de l’entretien des com-mandes, étiquetez tous les fils avant de les débrancher. Des erreurs de câblage peuvent entraîner un fonctionnement inadéquat et
dangereux. S’assurer que l’appareil fonctionne adéquatement une fois l’entretirn terminé.

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 with CSA C22.1 Canadian Electrical Code Part I if installed in Canada. A seperate circuit breaker must be installed per boiler (if required, the optional local pump FLA must be incorporated and sized accordingly). 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.

Refer to point of connection diagram in back of this

manual and the wiring diagram supplied with the boiler

for proper wiring connections.

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Cast Iron Condensing Boilers ­ Installation Manual

BOILER OPERATION

The system should be checked and bled after three days of operation.

Before proceeding read and fully understand the instructions contained in this manual. Do not attempt to operate this boiler if it has not been installed in accordance with the guidelines set forth in this manual. Failure to comply with this warning can result in extensive property damage, severe personal injury or death!

OPERATING INSTRUCTIONS
FOR YOUR SAFETY READ BEFORE OPERATING. ONLY QUALIFIED LICENSED SERVICE TECHNICIANS SHALL START, TROUBLESHOOT, AND SERVICE THIS APPLIANCE WITH APPROVED COMBUSTION ANALYZER. POUR VOTRE SÉCURITÉ LISEZ AVANT DE METTRE

Should overheating occur or the gas supply fail to shut off, turn off the manual gas control valve to the appliance. Do Not interrupt water flow through the boiler. En cas de surchauffe ou si l’alimentation en gaz ne s’arrête pas, fermez manuellement le robinet d’arrêt de l’admission de gaz. Hydronic Heating Boilers (Fill System)

EN MARCHE A. This appliance is equipped with an ignition device
which automatically lights the pilot. Do not try to light the pilot by hand. Cet appareil est muni d’un dispositif d’allumage qui allume automatiquement la veilleuse. Ne tentez pas d’allumer la veilleuse manuellement.

Open the make-up water valve and slowly fill the boiler and all of the radiation with water. Ensure that all bleed and drain valves are closed.

B. BEFORE OPERATING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will

Adjust the make-up water pressure regulator so a

settle on the floor.

minimum 5 psig, 82.7 kPa system pressure is WHAT TO DO IF YOU SMELL GAS

maintained at the highest point in the system piping. A minimum system pressure of 20 psig, 138 kPa must be maintained at boiler operating conditions. A minimum system pressure of 30 psig, 207 kPa fill pressure is required, at boiler operating conditions, on glycol mixtures within a closed loop.

· Do not try to light any appliance. · Do not touch any electric switch; do not use any phone
in your building. · Immediately call your gas supplier from a phone outside
of the building. Follow the gas suppliers instructions. · If you cannot reach your gas supplier, call the fire

Open the system bleed and drain valves, one at a time,

department.

to purge the air trapped in the heating system piping.

AVANT DE FAIRE FONCTIONNER, reniflez tout autour

With the boiler off, run the system pump for at least 30 minutes and bleed the system piping using the bleed valves. If strainers are used in the system piping the

de l’appareil pour déceler une odeur de gaz. Reniflez près du plancher, car certains gaz sont plus lourds que l’air et peuvent s’accumuler au niveau du sol.

make-up water valve should be closed and the strainers QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ:

checked and cleaned.

· Ne pas tenter d’allumer d’appareil.

The system expansion tank should be checked to ensure that tank air pressure equals cold static fill pressure.

· Ne touchez à aucun interrupteur; ne pas vous servir des téléphones se trouvant dans le bâtiment.
· Appelez immédiatement votre fournisseur de gaz depuis un voisin. Suives les instructions du

Start the boiler as described in the OPERATING INSTRUCTIONS below. Run the boiler for at least an hour. The system pump(s) and all radiation units must

fournisseur. · Si vous ne pouvez rejoindre le fournisseur, appelez
le service de incendies.

be operated during this time. Ensure that the make-up water valve is open.

C. Do not use this appliance if any part has been under water. Immediately call a qualified service technician

Shut the boiler off and open the bleed valves to purge the air trapped in the heating system piping. Close the make-up water valve and check and clean the strainers

to inspect the appliance and to replace any part of the control system and any gas control that has been under water.

and make-up water pressure reducing valve.

N’utilisez pas cet appareil s’il a été plongé dans l’eau,

Open the make-up water valve and adjust the system pressure if necessary.

même partiellement. Faites inspecter l’appareil par un tecnicien qualifié et remplacez toute partie du système de contrôle et toute commande qui ont été plongés dans

l’eau. 28

Cast Iron Condensing Boilers ­ Installation Manual

Operating Instructions – (5:1) Startup Procedure. (Refer to page (31) for 10:1 Field
Startup Instructions.) 1. STOP! Read the safety information above. If, at any
time, the appliance will not operate properly, follow the instructions “TO TURN OFF GAS TO APPLIANCE” and call your service technician or gas supplier.
2. Set the operating control to off and disable any outside (BMS) call for heat.
3. Turn off all electric power to the appliance.
4. Remove the front cover.
5. Close manual main shut-off valves 1 and 2 and the pilot gas shut-off valve, Figure 17.
6. Purge the gas piping up to the manual valve ahead of the main gas control of air. When the bleeding is complete, check all gas joints up to the gas valve for leaks.
7. Wait five (5) minutes to clear out any gas.
8. Install a fitting at the supply test port and connect a manometer having a minimum range of 20 in, 508 mm WC to it, Figure 17.
9. Remove the 1/8 in pipe plug from the pilot tee and connect a manometer having a minimum range of 6in, 154mm WC to it.
10. Open the manual main shut-off valves 1 and 2 and the pilot gas shut-off valve, Figure 17.
11. Place the “Remote/Local” switch to Remote.
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 18.
13. Slide the HeatNet controls low fire switch (on the HeatNet control board) to the low fire position.
Figure 18 – Control Panel

14. The boiler will begin the start sequence.
15. When the main display reads “PILOT RUNNING” and the flame current is 5VDC, switch the Honey well 7800 to the “test” position, Figure 18. This will hold the Honeywell 7800 in its ignition state.
16. Adjust the pilot pressure per the CHECKING, ADJUSTMENT & OPERATION on page 41.
17. To adjust the IGNITION value as shown in the display, place the S2′ Calibration switch located on the 3.0 Heat Net board to theCAL’ position. A reload message will be displayed then the calibrate screen. Press the Adjust’ button under the Ignition (%) setting. The value will turn green and the boiler will ramp to the ignition setting. Set the Blower speed, using the arrow keys, to provide the desired rate for ignition. When the adjustment is satisfactory, press the check key to save the setting. When complete place the S2′ switch back to the `NORM’ position.
18. Remove the demand from the 7800 control by disabling the low fire switch allowing the boiler to stop.
19. Close manual main shut-off valve 2 and the pilot gas shut-off valve, Figure 17. Remove the manometer fitting from the pilot tee and replace the plug.

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Cast Iron Condensing Boilers ­ Installation Manual

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 ignition transformer must be reversed and the test run again to insure that no flame is detected.

c. Adjust low fire 02-C02 by opening the low fire adjustment door located on the forward facing side of the main gas valve, (Figure 17). Inserting an allen wrench and rotating the allen screw clock-wise will increase the C02 and lower the 02; rotating counter clock-wise will decrease the C02 and increase the 02.
d. When the adjustment is satisfactory, press the check key to save the setting.
26. Setting the Maximum Calibration and High Fire Combustion values:

Warning Improper wiring of the ignition transformer can result in an explosion causing extensive property damage, severe personal injury or death!

a. Verify the S2′- Calibration switch located on the 3.0 HeatNet board is in theCAL’ position.

23. Open both manual main shut-off valves and the pilot gas shut-off valve.

24. Reset the Honeywell 7800. The boiler will start and will run at minimum input rate.

25. Setting the Minimum and Low Fire Combustion values: The boiler will cycle and achieve low fire status. Allow low fire to settle out for a few minutes and observe the combustion reading.
NOTE: The Calibration Settings represent the mapped signal sent to the blower and doesn’t reflect the (modulation %) as indicated on the Master/Member Screens.
a. Place the S2′ – Calibration switch located on the 3.0 HeatNet board to the CAL’ position. A reloading message will be displayed and then the calibrate screen.

b. Press the Adjust’ button under the Maximum setting. The value will turn green indicating that it can be changed. Adjust the Maximum value, using the arrow keys, to achieve the required combustion CO2/O2 (Table 11), and pressuredelta p, (Table 12), see pressure taps – (Figure 18 & 22). c. The high fire trim adjustment is located on the outlet flange, (Figure 17), of the gas valve. d. When the adjustment is satisfactory press the check key to save the setting. When complete, place theS2′ switch back to the `NORM’ position.
e. Allow the boiler to settle into min input and observe combustion readings to ensure the boiler is operating correctly. Make any required adjustments. When complete disable the low fire hold switch.
f. Follow the instructions in the HeatNet Control manual to allow adjustments required for high altitude installations.

b. Press the `Adjust’ button under the Minimum setting. The value will turn green. Adjust the Minimum value, using the arrow keys, to achieve the required combustion – C02/02 -(Table 11), and pressure delta p – (Table 12), see pressure taps (Figure 18 & 22), at low fire based on the desired turn down.
30

Cast Iron Condensing Boilers ­ Installation Manual

Operating Instructions – (10:1) Startup Procedure. (Refer to page (29) for 5:1 Field
Startup Instructions.) 1. STOP! Read the safety information above. If, at any
time, the appliance will not operate properly, follow the instructions “TO TURN OFF GAS TO APPLIANCE” and call your service technician or gas supplier.
2. Set the operating control to off and disable any outside (BMS) call for heat.
3. Turn off all electric power to the appliance.
4. Remove the front cover.
5. Close manual main shut-off valves 1 and 2 and the pilot gas shut-off valve, Figure 17.
6. Purge the gas piping up to the manual valve ahead of the main gas control of air. When the bleeding is complete, check all gas joints up to the gas valve for leaks.
7. Wait five (5) minutes to clear out any gas.
8. Install a fitting at the supply test port and connect a manometer having a minimum range of 20 in, 508 mm WC to it, Figure 17.
9. Remove the 1/8 in pipe plug from the pilot tee and connect a manometer having a minimum range of 6in, 154mm WC to it.
10. Open the manual main shut-off valves 1 and 2 and the pilot gas shut-off valve, Figure 17.
11. Place the “Remote/Local” switch to Remote.
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.
Figure 18a – Control Panel

14. The boiler will begin the start sequence.
15. When the main display reads “PILOT RUNNING” and the flame current is 5VDC, switch the Honeywell 7800 to the “test” position, Figure 18a. This will hold the Honeywell 7800 in its ignition state.
16. Adjust the pilot pressure per the CHECKING, ADJUSTMENT & OPERATION on page 41.
17. To adjust the IGNITION value as shown in the display, place the S2′ Calibration switch located on the 3.0 Heat Net board to theCAL’ position. A reload message will be displayed then the calibrate screen. Press the Adjust’ button under the Ignition setting. The value will turn green and the boiler will ramp to the ignition setting. Set the Blower speed, using the arrow keys, to provide the desired rate for ignition. When the adjustment is satisfactory, press the check key to save the setting. When complete place theS2′ switch back to the `NORM’ position.
18. Remove the demand from the 7800 control by disabling the low fire switch allowing the boiler to stop.
19. Close manual main shut-off valve 2 and the pilot gas shut-off valve, Figure 17. Remove the manometer fitting from the pilot tee and replace the plug.

31

Cast Iron Condensing Boilers ­ Installation Manual

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 ignition transformer must be reversed and the test run again to insure that no flame is detected.
Warning Improper wiring of the ignition transformer can result in an explosion causing extensive property damage, severe personal injury or death!
23. Open both manual main shut-off valves and the pilot gas shut-off valve.
24. Remove the demand from the 7800 control by disabling the low fire switch allowing the boiler to stop. Reset the Honeywell 7800.
25. Preliminary Air Shutter and Low Fire Combustion settings:
a. Enter calibrate screen by placing the calibrate switch ‘S2’ in the ‘CAL’ position, then select the “Start Calibrate” button on the bottom right hand side of the calibrate screen.
NOTE: The Calibration Settings represent the mapped signal sent to the blower and doesn’t reflect the (modulation %) as indicated on the Master/Member Screens.

b. Write down the Min Air Shutter Setting! This is a factory calculated setting. Press the ‘Adjust’ button under the Min Air Shutter setting. Using the arrows, bring Min Air Shutter to (20.0).
c. Give the boiler a call for heat by enabling the low fire switch on the HeatNet control board to the low fire position. Switch the Honeywell 7800 flame safeguard control to the “TEST” position, Figure 18a. This will hold the Honeywell 7800 in the purge state.
d. Take a measurement of the incoming air temperature and make note of the required low fire and high fire set point for both percent O2 and CO2. This set point can be found in the IOM, (Table 11). This reading will be needed during low and high fire combustion tests going forward. The air temperature should be measured as close to the filter box as possible.
e. Switch the Honeywell Flame Safeguard back to “RUN”.
f. Maintain the Min Air Shutter adjustment at 20.0 as the boiler lights and drops to low fire.
In calibrate, when the burner is lit, the boiler
will maintain 40% input for 20 seconds prior to dropping to low fire. Allow low fire to settle out for a few minutes. g. Begin slowly dropping to a Min Air Shutter setting that is 1 point greater than the factory set value, using the following routine. (Example: If the ‘Min Air Shutter’ factory setting is 9.8, stop decreasing input at 10.8.) h. Make a reduction in the Min air Shutter setting. Move in incrementally smaller steps while 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 check mark. The boiler will operate in a low fire condition.

32

Cast Iron Condensing Boilers ­ Installation Manual

26. Setting the Blower Clamp:
a. Measure the differential pressure across the Air Shutter, (Figure 18a & 22), and adjust the Blower Clamp so that the drop is 1.30 ± 0,05 in WC.
b. Once the blower is set, select the green check mark.
27. Setting the Maximum and High Fire Combustion values:
a. Verify the S2′- Calibration switch located on the 3.0 HeatNet board is in theCAL’ position. Then select “Adjust” on the Maximum tab. The value will turn green indicating that an adjustment can be changed.
b. Measure the signal pressure, (Figure 18a & 22). c. Adjust the Maximum value, if necessary, using
the arrow keys so that the signal pressure (delta-p) matches what is listed in the IOM, (Table 12a). Wait for combustion to stabilize.
28. Check/adjust combustion. Make adjustments to the Dungs high fire trim shutter, if necessary, to maintain proper combustion per the required setpoint taken from (Step 25d). The high fire trim adjustment is located on the outlet flange, (Figure 17), of the gas valve.

29. When the 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 theCAL’ 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 stabilize. c. Measure the signal pressure, (Figure 18a & 22) d. Adjust the Min Air Shutter value by 0.1 intervals,
using the arrow keys, to achieve the required pressure delta p – (Table 12a), see pressure taps – (Figure 18a & 22). e. Measure flue gas C02 concentration. To achieve the required combustion – C02/02 – (Table 11) adjust the low fire 02-C02 to the required set point recorded in (Step 25d). Access to this adjustment screw is accomplished by opening the low fire adjustment door located on the forward facing side of the main gas valve, (Figure 17). f. Repeat the above steps if necessary.
g. When the adjustment is satisfactory press the check key to save the setting. When complete, place the ‘S2’ switch back to the ‘NORM’ postion.
h. Disable the low fire hold switch to allow the boiler to go into standby.
i. Follow the instructions in the HeatNet Control manual to allow adjustments required for high altitude installations.

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Cast Iron Condensing Boilers ­ Installation Manual

KN-6, 10, 16, 20, 26, 30, 40 High Fire CO2 Adjustment Screw Clockwise = Increase
Counterclockwise = Decrease

The HeatNet High Turndown menu screen provides the following informational data:
a. The Modulation graph indicates the boiler input percentage.
b. The Air Shutter percentage indicates the shutter blade position at various operational cycle locations.
c. The O2/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. The Warning/Fault indicators are relevant for factory trouble shooting. LED’s will illuminate when a high turndown fault occurs. See the HeatNet (10:1) Supplement Control Manual for an explanation of each fault.

34

Cast Iron Condensing Boilers ­ Installation Manual

Instructions De Mise En Marche 1. ARRÊTEZ! Lisez les instructions de sécurité sur la portion supérieure de cette étiquette.
2. Réglez le thermostat à la température la plus basse.
3. Coupez l’alimentation électrique de l’appareil.
4. Cet appareil est muni d’un dispositif d’allumage qui allume automatiquement la veilleuse. Ne tentez pas d’allumer la veilleuse manuellement.
5. Fermer la vanne manuelle d’arrêt d’alimintation de gaz.
6. Attendre cinq (5) minutes pour laisser échapper tout le gaz. Reniflez tout autour de l’appareil, y compris près du plancher, pour déceler une odeur de gaz. Si vous sentez une odeur de gaz, ARRÊTEZ! Passez à l’étape B des instructions de sécurité sur la portion supérieure de cette étiquette. S’il n’y a pas d’odeur de gaz, passez à l’étape suivante.
7. Ouver la vanne manuelle d’arrêt d’alimintation de gaz.
8. Mettez l’appareil sous tension.
9. Réglez le thermostat à la température désirée.
10. Si l’appareil ne se met pas en marche, suivez les instructions intitulées couper l’admission de gaz de l’appareil et appelez un technicien qualifié ou le fournisseur de gaz.
TO TURN OFF GAS TO APPLIANCE 1. Set the operating control to its lowest setting.
2. Turn off 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. The boiler is idle with no interlocks in the fault condition.
DEMAND Pre-Purge 1. The blower operates at purge RPM. The water flow
interlock must `make’ within 15 seconds after the demand signal is initiated.
2. The Honeywell 7800 starts a 10 second purge delay once the air prove switch contacts close.
Pilot Run – %Input 1. The blower operates at minimum ignition setting. See the calibration section in the “KN-Series Control-IOM” to enter the calibration menus.
2. The ignition transformer is energized. The pilot solenoid valve opens for the 10 second pilot ignition trial.
Main Run %Input 1. The main gas valve opens.
2. The ignition transformer is de-energized.
3. The pilot solenoid valve closes.
4. The blower stays at the minimum input setting for 3 seconds then operates at demand % input. See the calibration section in the “KN-Series ControlIOM” to enter the calibration menus.
NO DEMAND Post-Purge
1. The main gas valve closes.
2. The blower operates at purge RPM for 10 seconds.
3. The boiler is idle with no interlocks in the fault condition.

35

Cast Iron Condensing Boilers ­ Installation Manual

Table 11 – Combustion Settings

KN-Series Whirlwind Bekaert Burner
w/Gas Orifice Slide Trim**

Inlet Air Temp.
-40°F -30°F -20°F -10°F
0°F 10°F 20°F 30°F 40°F 50°F 60°F 70°F 80°F 90°F 100°F

NG
Low Fire
10% 20%
6.5 7.2 6.6 7.3 6.7 7.4 6.8 7.5 6.9 7.6 7.0 7.7 7.1 7.8 7.2 7.9 7.3 8.0 7.4 8.1 7.5 8.2 7.6 8.3 7.7 8.4 7.8 8.5 7.9 8.6

CO2 % LPG

High

Low Fire

High

Fire

10% 20%

Fire

8.8

7.5 8.4

10.3

8.9

7.6 8.5

10.5

9.0

7.7 8.7

10.6

9.1

7.8 8.8

10.7

9.2

7.9 8.9

10.8

9.3

8.0 9.0

10.9

9.4

8.1 9.2

11.0

9.5

8.2 9.3

11.1

9.6

8.3 9.4

11.2

9.7

8.4 9.5

11.3

9.8

8.5 9.6

11.4

9.9

8.7 9.7

11.5

10.0

8.8 9.8

11.6

10.1

8.9 9.9

11.7

10.2

9.0 10.1

11.8

O2 %

Low Fire

High

10% 20%

Fire

9.4 8.3

5.1

9.2 8.1

5.0

9.0 7.9

4.8

8.9 7.8

4.6

8.7 7.6

4.4

8.5 7.4

4.2

8.3 7.2

4.0

8.2 7.1

3.9

8.1 6.9

3.8

7.9 6.7

3.7

7.8 6.5

3.5

7.6 6.4

3.3

7.4 6.2

3.1

7.2 6.1

3.0

7.1 5.9

2.9

**Located on outlet flange of gas valve. (Figure 17)

Due to job conditions, deviation from specified may be required ­ allow ± (0.2)% range adjustment.

Note: When units are installed with direct sealed combustion air, during periods of time with low outdoor temperature, it is possible for the room air to condense and possibly form frost on the air handling components of the boiler. Refer to (2015 ASHRAE Cold-Climate Buildings Design Guide)

Table 12 – Pressure Signal (P) – (Nat. Gas) Standard 5:1 Turdown Option

Firing Rate

KN-6
(Delta P) in WC

KN-10
(Delta P) in WC

KN-16
(Delta P) in WC

KN-20
(Delta P) in WC

KN-26
(Delta P) in WC

KN-30
(Delta P) in WC

KN-40
(Delta P) in WC

100%

7.50

7.00

12.00

10.50

10.00

8.00

8.80

33%

0.90

0.85

1.45

1.30

1.25

0.95

1.15

25%

0.65

0.60

1.00

0.90

0.85

0.70

0.75

20%

0.40

0.40

0.50

0.50

0.45

0.45

0.45

To determine signal in mm WC, multiply signal pressure by 25.4 – (See Factory Startup sticker for LP and Dual Fuel).

Table 12a – Pressure Signal (P) (NG/LP) with High Turndown Option

Firing Rate

KN-6
(Delta P) in WC

KN-10
(Delta P) in WC

KN-16
(Delta P) in WC

KN-20
(Delta P) in WC

KN-26
(Delta P) in WC

KN-30
(Delta P) in WC

KN-40
(Delta P) in WC

Fuel 100% 33% 25% 20% 15% 10%

NG LP NG LP NG LP NG LP NG LP NG LP NG LP 7.30 9.25 10.40 11.60 11.80 18.20 12.00 13.50 12.80 16.10 11.50 17.40 8.40 11.6 0.80 1.00 1.20 1.35 1.30 1.90 1.30 1.80 1.50 1.85 1.20 2.00 1.00 1.25 0.60 0.60 0.85 0.95 0.90 1.30 0.90 1.25 1.00 1.35 0.90 1.50 0.75 0.95 0.35 0.30 0.50 0.53 0.50 0.75 0.55 0.75 0.55 0.80 0.60 0.90 0.45 0.55 0.25 0.25 0.30 0.40 0.35 0.50 0.40 0.50 0.40 0.55 0.40 0.60 0.30 0.35 0.10 0.10 0.14 0.15 0.20 0.30 0.25 0.30 0.25 0.30 0.20 0.30 0.16 0.20

To determine signal in mm WC, multiply signal pressure by 25.4 – (See Factory Startup sticker for Dual Fuel).

36

Cast Iron Condensing Boilers ­ Installation Manual

KN-Series “HeatNet Control” Troubleshooting (Firing the KN Boiler)

Ametek Fan
Operate Blower Motor @ 0%

KN Control Functions Ignition Sequence

DISPLAY: STANDBY

CALL FOR HEAT?
YES

INPUTS: 1. MODBUS 2. AA 3.Heat Demand 4. 4-20ma 5. T1-T4

Start Circulator

J13 “CIRC”

Hand Shake

Ignition Contrrol (Honeywell S7800)

Interlocks OK?
NO YES

J5, J11A,J11B

Are we below the Temp Band?
NO

Setpoint – 1/2 Heat Band

YES, fire the boiler.

DISPLAY: HEATING:

Close the Last limit in the Limit String to Ignition
Control

J5 Pin 10 “LIMITS”

LIMITS

Operate Blower Motor @ 0%
Operate Blower Motor @ ~55%
Operate Blower Motor @ ~32%

J5 Pin 3

J4 Pins 4 & 8

NO

Have We “BLOWER” received the

“BLOWER”

signal?

If Yes, do

not operate blower.

YES

YES
“MAIN VALVE” greater than 7 VAC

J4 Pins 4 & 8
DISPLAY: PRE PURGE

NO PRE_PURGE

NO PILOT signal?

J5 Pin 2 “PILOT”

J4 Pins 4 & 8
DISPLAY: PILOT:

YES PILOT Ignition

NO MAIN signal?

J5 Pin 1 “MAIN”

Operate Blower Motor @ Min Fire, then Modulate to
maintain temp

J4 Pins 4 & 8
DISPLAY: RUN % 25

YES
1. Minimum fire rate 2. Hold for (x) secs. 3. Modulate to temp

BLOWER PILOT MAIN

NO

Limits OK?

TERM 6

“LIMITS”

YES

Send 120 VAC BLOWER signal
TERM 4 “MOTOR”

TERM 8 “PILOT”
After 10 Seconds send PILOT signal
FLAME?
YES
After 10 Seconds send MAIN
VALVE signal TERM 9 “MAIN”

37

Cast Iron Condensing Boilers ­ Installation Manual

CHECKING, ADJUSTMENT & OPERATION
Spark Gap The gap has to be measured and adjusted with the igniter removed from the boiler. Observe the trial for ignition to confirm that the spark is strong and continuous. If not, allow the electrodes to cool. Check and adjust the spark gap as shown in Figure 19. Electrode tips should face slightly downward.
Figure 19 – Spark Gap

Table 13

Recommended Electrode Insertion Depth, ± 1/4″

Model

DIM “A”

KN-40

11/2″

KN-30

11/2″

KN-26

11/2″

KN-20

11/2″

KN-16

13/4″

KN-10

21/4″

KN-6

21/4″

BEVEL UP

BEVEL DOWN

1/8 “A”

Pilot Adjustment
To check the pilot pressure close the manual main shutoff valve and the pilot gas shut-off valve, (Figure 17). Remove the 1/8 in pipe plug from the pilot test port (located as shown in (Figure 17) or on newer models as shown in (Figure 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 pilot pressure has been set within a range of (2.5 in.- 3.5 in WC) at test port location (Figure 17); if applicable – (2.0 in.-3.0 in WC) at test port location (Figure 20).

AIOM-016_C
To adjust the pilot the following steps must be taken:
1. Remove the pilot gas pressure regulator cap.
2. Turn the pressure regulator adjustment screw clockwise to increase the pressure and counterclockwise to decrease it.
3. Replace the pressure regulator adjustment screw cap.
Never force the regulator adjustment screw beyond the stop limits or damage to the regulator will occur!

38

Cast Iron Condensing Boilers ­ Installation Manual

Figure 20 – Pilot Flame
1 1/2 TO 2″ LONG BLUE FLAME

TEST PORT
PILOT TUBE BURNER

PILOT FLAME
Pilot flame UV signal Before you check the pilot signal you need to make sure the polarity of the 120v supply to the ignition transformer is correct. To do this close the manual main shut-off valve 2 (Figure 17) and the manual pilot shut-off valve. With the unit powered generate a call for heat. The boiler will start to go through it start up sequence. During the ignition/pilot sequence observe the lights on the Honeywell 7895C. The pilot light should come on but not the flame light. If the flame light comes on along with the pilot light, interrupt the call for heat and turn off the main power. Reverse the 120v supply leads to the Honeywell 652B ignition transformer and run this test again. With this done the flame signal should be between 3vdc and 5vdc. Check the voltage on the test connections of the Honeywell 7895C’s amplifier with a dc voltmeter.
Ignition Safety To test the ignition safety shutoff device, close the manual shutoff valve 1 (Figure 17) in the gas supply line. Within 5 seconds of main burner flame extinction, the main gas valve solenoid should close. The control board will lockout and display “LOW GAS PRESSURE”. Open the manual shutoff valve in the gas supply line and reset the control board by toggling the power switch.
To confirm the input of the unit follow the instructions in the INPUT RATE section below.
Input Rate, Natural Gas 1. Turn off all other gas appliances that use the same gas meter as the boiler.
2. Call your gas supplier and ask for the heating value of the gas (Btu per cu/ft).
3. Start the boiler and let it run for 15 minutes.
4. With the boiler operation clock the time that it takes to 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 Water Cutoff Ensure that the low water cutoff device(s) function properly.
Test in accordance with the manufacturer’s instructions included with the device(s).
DIAGNOSTICS
The KN has a display that indicates the sequence of operation, Figure 18. The display will also list faults should the unit fail to operate. An explanation of each fault is listed below.
STANDBY KN: Indicates that power is being supplied to the unit and there is no call for heat.
STANDBY OPERATING LIMIT: Indicates that the operating limit if used is open.
HONEYWELL ALARM “flashing”: Indicates that there is a call for heat and the Honeywell 7895C is locked out.
STANDBY START DEMAND: Indicates that there is a call for heat and the Honeywell 7895C is not functioning or is locked out.
STANDBY WATER LIMIT: Indicates that either the high limit, low water cut off, or both are open without a call for heat.
LOCKOUT WATER LIMIT: Indicates that either the high limit, low water cut off, or both are open with a call for heat.
STANDBY GAS PRESSURE: Indicates that the low gas pressure switch or the high gas pressure switch if used is open without a call for heat.
LOCKOUT GAS PRESSURE: Indicates that the low gas pressure switch or the high gas pressure switch if used is open with a call for heat.
WAITING FOR FLOW: Indicates that minimum flow hasn’t been achieved.
FAULT INSUFFICIENT FLOW: Indicates that inadequate flow is present.
LWCO LOCKOUT: Indicates low or no water in the boiler. 39

Cast Iron Condensing Boilers ­ Installation Manual

MAINTENANCE
Disconnect electrical power and close the manual gas shut off valve before performing maintenance or severe personal injury may result!
Servicing, inspection and adjustment must be done by a trained technician in accordance with all applicable local and national codes. Improper servicing or adjustment can damage the boiler!
The boiler must be inspected at least once a year and before each heating season. Make sure that combustion readings and air box pressures are taken on each boiler and match the desired emissions outlined under the specification in the Installation Manual — adjust as necessary. Accessing the burner compartment isn’t necessary during normal maintenance unless combustion values or air box pressures don’t meet specification. The condensate pan must be inspected and cleaned as required.
Improper burner servicing can result in premature burner failure voiding the warranty!
Burner Removal & Inspection
Wear a tightly fitted dust mask when servicing the burner and gently handle the burner and its gasket to prevent inhalation of airborne fibers.
Do not attempt to remove the burner without having a burner gasket kit on hand.
Heat Exchanger Cleaning In the unlikely event that the heat exchanger becomes blocked consult the factory for the proper cleaning procedure.
Air Intake & Vent System Thoroughly inspect the air intake and vent systems for any signs of blockage, corrosion or leakage and periodically clean screen in the vent terminal (where applicable). Immediately replace any unsound vent system piping. Inspect the air filter and replace when required.
Condensate Pan Cleaning Remove the (6) bolt – base pan door from the front of the boiler. Using a hose, flush out any residual material in the base pan through the condensate drain opening. Re-install the base door with a replacement gasket (if required). Flush the drain trap and refill with 50% water/ glycol mix to prevent evaporation in the trap.
40

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 not, replace them.
3. The flow sensor isolation valves must be open in order for proper flow.
In the unlikely event that the SIKA flow sensor requires cleaning, in order to flush the flow sensor, close the ball valve installed upstream of the flow sensor, connect a hose to the drain fitting provided and open the drain valve. Drain approximately a gallon of water to properly flush the flow sensor. The drain is then closed and the upstream valve re-opened.
4. The relief valve should not weep or discharge water at normal system pressure – this may be due to thermal expansion in a closed water supply system. If it does contact a qualified service technician to have it inspected. NEVER try to clean or repair the relief valve! If the valve fails to operate properly, have it replaced!
5. The aquastat high limit controls the maximum water temperature in the boiler. It is adjustable from 100°F, 38°C to 240°F, 115°C. If the water temperature reaches the set temperature before the demand for heat has been met, the aquastat high limit should shut the boiler off. The water temperature should never exceed the maximum set point of 240°F, 115°C. The aquastat high limit cannot be repaired. If it fails to function properly replace it.
6. Visually check the pilot and main burner flames to ensure proper operation, see Figures 20 & 21.
Visual flame appearance with proper combustion will have a red and blue striped appearance at low fire and flecked areas of red with a majority of blue across the metal mesh burner at high fire. Areas of deep red indicate an infrared condition requiring a combustion adjustment to reduce CO2 levels.
Figure 21 – Main Burner Flame
TIGHT BLUE FLAME
AIOM-018_B
YELLOW FLOATING FLAME

Cast Iron Condensing Boilers ­ Installation Manual

Figure 22 – KN-6, 10, 16, 20, 26, 30 and 40 Pressure Switches

FILTER BOX – TOP VIEW

IGNITOR BLOCK ASSEMBLY
UV SCANNER

ORANGE

AIR PUMP

NO INTERNAL CONNECTION – HTD ONLY

1

2

3

4

5

6

PILOT

1 & 3 BARBS – INTERNAL FILTER BOX REFERENCE
3 & 4 (SIGNAL PRESSURE) BARBS CAPPED EXTERNALLY REFERENCE CONNECTIONS FOR FIELD/FACTORY

ORANGE BLUE

2 1

BARB FITTINGS

COMPRESSION FITTINGS

2 ORANGE 1 BLUE

RH CONTROL ENCLOSURE PANEL

PS1 BLOWER PROVE PRESSURE SWITCH
REAR P1 (+)

FRONT(+)
PS2 BLOCKED FLUE PRESSURE SWITCH

REAR(-)

PILOT GAS TRAIN

FRONT P2 (-)

FRONT (+)

REAR (-)

PS3 BLOCKED INLET PRESSURE SWITCH

GAS VALVE ASSEMBLY

INSIDE SERVICE PANEL

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

KN-6, 10, 16, 20, 26, 30 and 40 Pressure Switches (10:1)

FILTER BOX – TOP VIEW

IGNITOR BLOCK ASSEMBLY
UV SCANNER

ORANGE

PURPLE

PURPLE GREEN

1

2

3

4

5

6

PILOT

AIR PUMP
1 & 3 BARBS – INTERNAL FILTER BOX REFERENCE 3 & 4 (SIGNAL PRESSURE) AND 5 & 6 (AIR SHUTTER SIGNAL PRESSURE) BARBS CAPPED EXTERNALLY – REFERENCE CONNECTIONS FOR FIELD/FACTORY

PURPLE BLUE

2 1

2 PURPLE 1 BLUE

RH CONTROL ENCLOSURE PANEL

PS1 BLOWER PROVE PRESSURE SWITCH
REAR P1 (+)

FRONT(+)
PS2 BLOCKED FLUE PRESSURE SWITCH

REAR(-)

PILOT GAS TRAIN

FRONT P2 (-)

FRONT (+)

REAR (-)

PS3 BLOCKED INLET PRESSURE SWITCH

GAS VALVE ASSEMBLY

INSIDE SERVICE PANEL

SWITCH SET POINTS IN INCHES OF WATER COLUMN

SWITCH

FOR

KN – 10:1

PS1

BLOWER PROVE

-0.40

PS2

BLOCKED FLUE

-5.50

PS3

BLOCKED INLET

-3.00

41

Cast Iron Condensing Boilers ­ Installation Manual

Figure 23 – KN-6, KN-10, KN-16, KN-20, KN-26, KN-30 and KN-40 Relays, Interlocks and Boiler Status

The Highest priority
Low Voltage Interlocks, 24VAC

SYSTEM FLOW PROVE ———

1

Low Water Cutoff——————-

2

Variable Frequency Drive ——–

3

Gas Pressure (High & Low) —–

4

Spare for user or Factory ——

5

Operator——————————

6

Water Flow Switch—————–

7

Factory ——————————

8

Remote 120 VAC Operator
JUMPER WIRE if not used

Stage Control
Damper Control Local Pump or
Power Open/ Power Close Valve

Alarm

DHW Pump or Power Open/ Power Close Valve

USB and Flashdrive Ports: Used by HeatNet Pro and updating firmware.
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 proving switch from Combustion Air Damper.

42

Cast Iron Condensing Boilers ­ Installation Manual
START-UP REPORT

DATE: TECHNICIAN: COMPANY: PHONE NUMBER:

JOB NAME: LOCATION: MODEL: SERIAL #:

PRE-STARTUP CHECK LIST

NO VISIBLE DAMAGE TO UNIT PIPING PROPERLY CONNECTED BOILER CIRCULATOR WIRED VENT/STACK CONNECTED

INLET AIR FILTER INSTALLED AND CLEAN PROPER SERVICE CLEARANCES PROVIDED PUMP RUNNING, HEAT EXCHANGER FULL GAS LINES PURGED, NO LEAKS, NO MISSING TEST PLUGS

BOILER START UP SEQUENCE
Note: Locate the S2 Calibration Switch and low fire hold switch in the bottom- right of the electrical panel on the main HeatNet board. Also locate the manometer test ports at the bottom of the filter box. 1. Perform pre-start up checks and set up: (follow section “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 section “Checking, Adjustment & Operation”) (flame signal should read 5.0 VDC). 5. Set low and high fire combustion values; (follow section “Operating Instructions”- selected turndown
procedure). 6. Record low and high fire combustion values (page 2 of Start-up Report). 7. Check all combustion results using a calibrated flue gas analyzer. 8. Release the LOW FIRE switch to place boiler in standby.

In addition to completing the KN-Series start-up report, complete the control set-up information in the rear of the HeatNet manual.

43

Cast Iron Condensing Boilers ­ Installation Manual

COMBUSTION ANALYSIS
GAS INLET PRESSURE (WC) CO2 O2 CO (PPM) NET STACK TEMPERATURE SIGNAL PRESSURE (DELTA P – WC) AIR SHUTTER (DELTA P – WC) (10:1) MIN AIR SHUTTER CALIBRATION (10:1) BLOWER CLAMP CALIBRATION (10:1) MINIMUM CALIBRATION (5:1) MAXIMUM CALIBRATION TACHOMETER

MINIMUM FIRING RATE
INCHES WC % %
PPM oF
INCHES WC INCHES WC
% % % N/A RPM

100% FIRING RATE
INCHES WC % %
PPM oF
INCHES WC N/A N/A N/A N/A % RPM

SAFETY TEST CHECKLIST
FLOW SWITCHES (By Others) LOW WATER CUT-OFF

AIR SWITCH HIGH LIMITS

FLAME SAFEGUARD

COMMISSIONING THE BOILER

UNIT CYCLED MINIMUM OF 15 TIMES CUSTOMER INSTRUCTED ALL COVERS REPLACED CUSTOMER GIVEN MANUAL TARGET TEMPERATURE SET PER CUSTOMER

THE DELTA T BETWEEN THE HEATER INLET AND OUTLET IS CRITICAL TO PROPER FLOW. BEFORE YOU LEAVE THE JOBSITE, YOU MUST RECORD THE DELTA T. THIS READING SHOULD NOT EXCEED 100 oF, 55 oC, NOR BE LOWER THAN 20oF, 11.1oC.

COMMISSIONED BY: __ (SIGNATURE)
DATE: ____

DELTA T =

ADDITIONAL NOTES AND COMMENTS

44

Cast Iron Condensing Boilers ­ Installation Manual Figure 24 – KN-6, 10, 16, 20, 26, 30 and 40
45

Cast Iron Condensing Boilers ­ Installation Manual

SERVICE AND REPLACEMENT PARTS LIST – KN-6, KN-10, KN-16, KN-20, KN-26, KN-30 and KN-40

Ref 1 2
3

Name of Part Supply Sensor w/Well Flow Sensor (VVX15) Flow Sensor (VVX15) Replacement Kit Flow Switch (IFS-1) Flow Switch (FS251) 30 psi Relief Valve

50 psi Relief Valve

75 psi Relief Valve

100 psi Relief Valve

4 Air Vent NS Raised Air Manifold 5 High Limit Aquastat (Manual Reset)
Well 1/2″ 6 High Limit Aquastat (Auto Reset)
Well 1/2″ 7 T&P Gauge ( 30 & 50 psi)
T&P Gauge ( 75 & 100 psi) 8 Return Sensor w/Well 9 Filter Box Cover
10 Sight Glass Sight Glass Gasket Inner Sight Glass Gasket
11 Air Filter
12 Filter Box Weldment
13 Filter Box Panel, RH
Filter Box Panel, RH (10:1)
NS Gas Orifice (NG) Must order orings below

NS Gas Orifice (LP) Must order orings below

NS Orings, Gas Orifice

Part No. 02-4284 13-00526-002 75-00582-001 14-0201 14-00001-001 22-1805 22-1809 22-1820 22-1807 22-1810 22-1821 22-1803 22-1811 22-1822 22-1808 22-1812 22-1823 13-00005-004 13-00402-001 01-00001-001 14-00054-001 14-00151-001 14-00053-001 14-00151-002 20-1021 20-1020 02-4284 03-00370-002 03-00370-001 03-00370-000 60-4280 05-00103-001 59-1064 20-00016-002 20-00016-001 20-00016-000 75-00305-002 74-00305-001 74-00305-000 74-00308-002 74-00308-001 74-00308-000 74-00309-002 74-00309-001 74-00309-000 10-00001-006 10-00001-005 10-00001-014 10-00001-005 10-00001-007 10-00001-003 10-00001-002 10-00001-001 10-00001-012 10-00001-011 10-00001-013 10-00001-010 10-00001-009 10-00001-008 10-00001-007 10-00001-005 95-00002-153 95-00002-157

Model Size with Item Quantities Below

KN-6 KN-10 KN-16 KN-20 KN-26 KN-30 KN-40

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1 (10:1)

1

1 (10:1)

1

1

2

1

1

1

1 (10:1)

1

1

1

1

2

1

1

1

1

1

1

2

1

1

1

1

1

1

2

46

Cast Iron Condensing Boilers ­ Installation Manual

SERVICE AND REPLACEMENT PARTS LIST – KN-6, KN-10, KN-16, KN-20, KN-26, KN-30 and KN-40

Ref NS

Name of Part Conversion Kit (LP to NG)

NS Conversion Kit (NG to LP)
NS Gasket, Blower/Filter Box NS 1/4″ Aluminum Tubing NS UV Flame Sensor, C7027 NS 3″ Supply & Return Casting
4″ Supply & Return Casting 14 Block / Sections 15 Jacket Assembly NS Gasket, Blower Adapter/Upper Cover NS Flue Adapter
16 Blower Replacement Kit
NS Clear RTV Sealant NS Gasket, Blower / Filter Box NS Gasket, Blower/Blower Adapter 18 Upper Cover
18a Burner
NS Burner Gasket Kits
NS Fiber Gasket – Burner to Ceramic Chamber

Part No. 75-00574-001 75-00574-002 75-00574-008 75-00574-003 75-00574-009 75-00574-004 75-00574-005 75-00574-006 75-00574-007 75-00575-001 75-00575-002 75-00575-008 75-00575-003 75-00575-004 75-00575-005 75-00575-006 75-00575-007 06-00010-001 89-00005-021
02-5206 01-00051-001 01-00054-001

Model Size with Item Quantities Below KN-6 KN-10 KN-16 KN-20 KN-26 KN-30
1 1
1 (10:1) 1
1 (10:1) 1 1 1

1 1
1 (10:1) 1 1 1 1

1

1

1

1

per foot

1

1

1

1

1

1

2

2

2

2

2

2

Consult Customer Service – model and serial number required

06-00017-001

1

1

1

06-00009-001

1

1

1

09-00002-003

1

1

09-00002-002

1

1

09-00002-001

1

1

09-00002-005

75-00567

1

1

75-00572-001

1

1

75-00573-001

1

1

75-00585-001

66-00103-001

3

3

3

3

3

3

06-00018-001

1

1

06-00016-001

1

1

06-00008-001

1

1

1

1

75-00206-006

1

75-00206-005

1

75-00206-004

1

75-00206-003

1

75-00206-002

1

75-00206-001

1

75-00206-000

74-00233-006

1

74-00233-005

1

74-00233-004

1

74-00233-003

1

74-00233-002

1

74-00233-001

1

74-00233-000

75-00579-006

1

75-00579-005

1

75-00579-004

1

75-00579-003

1

75-00579-002

1

75-00579-001

1

75-00579-000

06-00002-006

1

06-00002-005

1

75-00580-004

1

75-00580-003

1

75-00580-002

1

75-00580-001

1

75-00580-000

KN-40
1
1 1 1 2 1 1 1 3 1
1
1
1
1

47

Cast Iron Condensing Boilers ­ Installation Manual

SERVICE AND REPLACEMENT PARTS LIST – KN-6, KN-10, KN-16, KN-20, KN-26, KN-30 and KN-40

Ref 18b

Name of Part Combustion Chamber

NS Burner Rebuild Kits

NS Burner Replacement Kit (less burner)

19 Drain Pan Assembly

NS RTV Red Sealant 10 Oz Tube NS Pilot Tube
Pilot Orifice NG Pilot Orifice LP Pilot Orifice Adapter
21 Ignitor Block Assembly 21a Electrode
Gasket, Electrode Washer, Electrode (2 per) NS Ignition Cable 24″ NS Ground Cable 15″ 22 Condensate Trap Assembly Condensate Trap Cap 22a Condensate Trap Assembly (10:1) 22b Switch Level 23 Manual Shutoff Valve 1″ Manual Shutoff Valve 1 1/2″ Manual Shutoff Valve 2″ 24 Pilot Gas Regulator 25 Pilot Gas Valve V4046C 26 1/8 Gas Cock 27 Manual Shutoff Valve 1″ Manual Shutoff Valve 1 1/2″ Manual Shutoff Valve 2″ 28 Gas Valve MBC MBC Filter Kit Gas Valve MBC MBC Filter Kit Gas Valve MBC 28a Low Gas Pressure Switch 28b High Gas Pressure Switch 30 Drain Pan Bolt Assembly 31 Drain Pan Clean Out Cover 32 Drain Pan Clean Out Cover Gasket 39 #751 LWCO less Case LWCO Probe NS Rocker Switch (Green) 43 Touchscreen Display w/Enclosure 44 Power Switch, Rocker

Part No. 05-00003-001 05-00004-001 75-00244-004 75-00244-003 75-00244-002 75-00244-001 75-00244-000 75-00540-006 75-00540-005 75-00540-004 75-00540-003 75-00540-002 75-00540-001 75-00540-000 75-00543-006 75-00543-005 75-00543-004 75-00543-003 75-00543-002 75-00543-001 75-00543-000 75-00202-006 75-00202-005 75-00202-004 75-00202-003 75-00202-002 75-00202-001 75-00202-000 66-00101-001 10-00105-002 10-00105-001 10-00050-001 10-00050-002 10-00101-002 10-00101-001
70-1345 04-1343-001 05-00102-002
57-4709 16-00004-001 16-00008-001 75-00234-001
04-00110 75-00234-003 14-00401-001
02-1575 02-1578 84-01300-006 11-00301-001 11-00401-001 84-01268-001 02-1575 02-1578 84-01300-006 11-00001-001 11-00109 11-00002-001 11-00110 11-00003-001 11-00201-001 11-00202-001 75-00203-001 74-00202-001 06-00001-001 14-00202-001 14-00202-002 58-1555 40-00752-003 58-1536

Model Size with Item Quantities Below

KN-6 KN-10 KN-16 KN-20 KN-26 KN-30 KN-40

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

2

2

2

2

2

2

1

1

1

1

1

1

1

4

4

4

4

4

4

4

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

2

2

2

2

2

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

48

Cast Iron Condensing Boilers ­ Installation Manual

SERVICE AND REPLACEMENT PARTS LIST – KN-6, KN-10, KN-16, KN-20, KN-26, KN-30 and KN-40

Ref 49 52 NS 57 NS 59 60 61
63 NS NS NS 64 65 66
67 68 69 70 71
72
73 NS NS

Name of Part Ignition Transformer Gas Train Shroud Jacket Panel Insulation, 2″ Foil Back HNet V3.0 Board Replacement Kit Ribbon Cable (Touchscreen) 50VA Transformer 250VA Transformer Blower Relay, Solid State
Flame Safeguard RM7895C Display Module S7800 Purge Timer ST7800 UV Amplifier, R7849A Pressure Switch NS2-0334-00 3.0″ WC Pressure Switch NS2 5.5″ WC Pressure Switch – HUBA 0.10″ WC Bracket, Pressure Switch Air Pump Sensor, O2 (10:1) Power Supply (10:1) Board (10:1) Shutter Box
Gasket, Shutter Box to Filter Box
Cover, Stepper Motor (10:1) Touchscreen Overlay HeatNet Overlay

NS Rating Label

Part No. 16-00353-001 74-00221-001
10-5008 75-00570 40-00269 26-3211 15-00003-001 15-00106 15-00105-001 16-00257-001 16-00258-001 02-4014 16-00256-001 14-00304-001 14-00306-001 14-00301-001 14-00302-001 09-1518 16-00156-001 48-00803-001 40-00757-001 75-00355-001 75-00355-000 06-00031-001 06-00031-000 03-00426-001 82-00410-001 82-00412-006 82-00412-005 82-00412-004 82-00412-003 82-00412-002 82-00412-001 82-00412-000 82-00004-001

Model Size with Item Quantities Below

KN-6 KN-10 KN-16 KN-20 KN-26 KN-30 KN-40

1

1

1

1

1

1

1

1

1

1

1

1

1

1

Per square foot

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

49

Cast Iron Condensing Boilers ­ Installation Manual

NOTICE!

MACODE-3
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 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 detector with an alarm and battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors.
a. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.
b. In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.
2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.
3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, “GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.
4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a)1 through 4.
Improper venting can result in excessive levels of carbon monoxide which can cause severe personal injury or death!

In the Commonwealth of Massachusetts, the installation must be performed by a licensed plumber or gas fitter.
(b) Exemptions
The following equipment is exempt from 248 CMR 5.08(2)(a) 1 through 4: 1. The equipment listed in Chapter 10 entitled “Equipment Not
Required To Be Vented” in the most current edition of NFPA 54 as adopted by the Board; and 2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes. (c) MANUFACTURER REQUIREMENTS – GAS EQUIPMENT VENTING SYSTEM PROVIDED.
When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall include: 1. Detailed instructions for the installation of the venting system
design or the venting system components; and 2. A complete parts list for the venting system design or venting
system. (d) MANUFACTURER REQUIREMENTS ­ GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED.
When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases, but identifies “special venting systems”, the following requirements shall be satisfied by the manufacturer: 1. The referenced “special venting system” instructions shall
be included with the appliance or equipment installation instructions; and 2. The “special venting systems” shall be Product Approved by the Board, and the instructions for that system shall include a parts list and detailed installation instructions. (e) A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation.
Improper venting can result in excessive levels of carbon monoxide which can cause severe personal injury or death!

50

Cast Iron Condensing Boilers ­ Installation Manual
KN+ and 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 supplied boiler parts (“Products”) 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 whichever comes first. If upon examination by the manufacturer the product is shown to have a defect in material or workmanship during the warranty period, the manufacturer will repair or replace, at its option that part of the product, which is shown to be defective. Twenty-Five Year Warranty The manufacturer warrants to the original owner at the original installation site that the products Cast Iron Heat Exchanger (Cast Iron Block) will be free from defects in material or workmanship and against failure due to condensate corrosion, for a period of twenty-five (25) years (non-prorated) from the date of shipment from the factory. This warranty will cover damage due to thermal shock, such as leaks to the cast iron sections, when installed as a closed loop hot water boiler. If upon examination by the manufacturer the product is shown to have a defect in material or workmanship during the warranty period, the manufacturer will repair or replace, at its option the products Cast Iron Heat Exchanger, which is shown to be defective. Five Year Warranty The manufacturer further warrants to the original owner at the original installation site that the products Secondary Heat Exchanger will be free from defects in material, workmanship, condensate corrosion and leaks due to thermal shock, when installed as a closed loop hot water boiler, for a period of five (5) years (non-prorated) from the date of shipment from the factory. If upon examination by the manufacturer the product is shown to have a defect in material or workmanship during the warranty period, the manufacturer will repair or replace, at its option the products Secondary Heat Exchanger, which is shown to be defective. This Limited Warranty does not Apply: (a) This warranty does not cover damage due to water side corrosion, scaling, sooting or to improper installation 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 follow these guidelines will void the warranty. (b) If the product has been subjected to misuse or neglect, has been accidentally or intentionally damaged, has not been installed, maintained or operated in accordance with the furnished written instructions, or has been altered or modified in anyway by any unauthorized person. (c) To any expenses, including labor or material, incurred during the removal or reinstallation of the product or parts thereof. (d) To products which were not installed and or serviced by a qualified contractor and or serviceman. (e) To burners, jackets, controls and other auxiliary equipment furnished by the manufacturer, but manufactured by others. Any warranties for such items shall be limited to those warranties offered by the original equipment manufacturer. (f) To any workmanship by any installer of the product. This limited Warranty is Conditional Upon: (a) Shipment, to the manufacturer, of that part of the product thought to be defective. Goods may only be returned with prior written approval of the manufacturer. All returns must be freight prepaid. (b) Determination in the reasonable opinion of the manufacturer that there exists a defect in material or workmanship. Repair or replacement of any part under this Limited warranty shall not extend the duration of the warranty with respect to such repaired or replaced part beyond the stated warranty period. THIS LIMITED WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EITHER EXPRESSED OR IMPLIED, AND ALL SUCH OTHER WARRANTIES, INCLUDING WITHOUT LIMITATION IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY DISCLAIMED AND EXCLUDED FROM THIS LIMITED WARRANTY. IN NO EVENT SHAL

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