Hydrotherm KN - mesteksa.commesteksa.com/fileuploads/Literature/Hydrotherm... · support the boiler block during as-sembly, then removed afterward. Step 2 Oil top surface of runner

Thismanualisintendedonlyforusebyaqualifiedheatinginstaller/technician.Readandfollowthismanual,allsupplementsandre-latedinstructionalinformationprovidedwiththeboiler.Install,startandservicetheboileronlyinthesequenceandmethodsgiveninthismanualandthedocumentslistedabove.Failuretodosocanresultinseverepersonalinjury,deathorsubstantialpropertydamage.

Do not use the boiler during construction.Constructiondustandparticulate,particularlydrywalldust,willcausecontaminationoftheburner,resultinginpossibleseverepersonalinjury,deathorsubstantialpropertydamage.Theboilercanonlybeoperatedwithadust-freeairsupply.Followtheinstructionmanualprocedurestoductairtotheboilerairintake.Iftheboilerhasbeencontaminatedbyoperationwithcontaminatedair,followtheinstructionmanualguidelinestoclean,repairorreplacetheboilerifnecessary.

P/N 42-9551 Copyright 2011 Mestek, Inc.

Hydrotherm®

Gas-fired direct ventCast iron boilers

Model KN-20 only

-SeriesKN

Field assembly instructions

Also read and follow:

KN Series Gas Boiler Installation & Operating Instructions and KN HeatNet Control Manual

2 P/N 42-9551

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

Hazard iconsYou will find the following icons throughout this manual. (English/French)

The WARNING icon indicates a hazard that can cause severe personal injury, death or substantial property damage.

The CAUTION icon indicates a hazard that will or can cause minor personal or property damage.

The NOTICE icon calls out special instructions that are important, but are not related to hazards.

Other manuals

You must read and follow this manual, the KN Series Gas Boiler Installation and Operating Instructions, the KN HeatNet Control manual and all additional materials supplied with the boiler. Failure to do so can result in severe personal injury, death or substantial property damage.

Boiler/control installa-tion and setup

After completing assembly of the KN boiler, follow all instructions in the Installation and Operation Instructions and Control Manual for installation, start-up and testing.

Contents and information

Read before beginning the installation 5

Boiler ratings and specifications 6

Installation site preparation 7

Prepare the boiler 10

Water piping 11

Gas piping 18

Wiring a single boiler 20

Control setup 25

Vent piping (and air piping when used) 28

Condensate drain line 29

Fill and test the system 30

Starting the boiler 32

Annual start-up 41

Maintenance 42

Replacement parts 46

Appendix A — suggested wiring 48

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Customer service and technical support

Direct all questions to your HydroTherm distributor or contact the HydroTherm 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.

Claims for damage or missing components must be filed immediately against the transportation company by the consignee.

Read before proceeding

Codes and standards

Code compliances

Allaspectsoftheboilerinstallationmustconformtotherequirementsoftheauthorityhavingjurisdiction,or,intheabsenceofsuchrequirements,to the National Fuel Gas Code, ANSI Z223.1/NFPA 54-latest revision.Whererequiredbytheauthorityhavingjurisdiction,theinstallationmustconformtotheStandardforControlsandSafetyDevicesforAutomati-callyFiredBoilers,ANSI/ASMECSD-1.

InCanada,theinstallationmustbeinaccordancewiththerequirementsofCSAB149.1or .2,InstallationCodeforGasBurningAppliancesandEquipment.

Before assembling the boiler . . .

Verify boiler rating and gas supply• Before assembling and installing the boiler, check the ratings to en-

surethattheunithasbeensizedproperlyforthejob.

• Ensurethattheboilerwillbesetupforthetypeofgasavailableattheinstallationsite.

Verify location is suitable• Ensure the availability of an adequate electrical supply, uncontami-

natedair forcombustion,andthatvent(andair)pipingcanbecor-rectlyinstalled.

• Ensure the boiler can be connected to system water piping and gassupply.

• Theboilermustnotbeexposedtodrippingorsprayingwateror torain.

• Ifreplacinganexistingboiler,findoutwhatcausedtheboilertofailbeforeinstallinganewboiler.Correcttheproblemsthatledtofailure,orthefailuremayhappentothenewboiler.

Attention:

Use of an approved dust respirator is strongly recommended when handling the insulating com-ponents of the boiler.

Electrical shock hazard—Disconnectallelectricalpowersourcestotheboilerbeforemakinganyelectricalconnections.

Labelallwirespriortodisconnectionwhenservicingcontrols.Wiringerrorscancauseimproperanddangerousoperation!Verifyproperoperationafterservicing.

Failuretocomplywiththeabovecouldresultinseverepersonalinjury,deathorsubstantialpropertydamage.

TheelectricalconnectionstothisboilermustbemadeinaccordancewithallapplicablelocalcodesandthelatestrevisionoftheNationalElectricalCode,ANSI/NFPA-70.InstallationshouldalsoconformtoCSAC22.1CanadianElectricalCodePartIifinstalledinCanada.Installasepa-rate120volt15ampcircuitfortheboiler.Aproperlyratedshut-offswitchshouldbelocatedattheboiler.Theboilermustbegroundedinaccordancewiththeauthorityhavingjurisdiction,orifnone,thelatestrevisionoftheNationalElectricalCode,ANSI/NFPA-70.

Linevoltagefieldwiringofanycontrolsorotherdevicesmustusecopperconductorswithaminimumsizeof#14 awg.Useappropriatewiringmaterialsforunitsinstalledoutdoors.

DONOTopenanygasvalve,orattempttofiretheboiler,untilallboilershavebeensetupandverifiedfollowingtheinstructionsintheKNSeriesGasBoilerInstallation&OperatingInstructions.

Failuretocomplycouldcauseaboilerfailure,leadingtopossibleseverepersonalinjury,deathorsubstantialprop-ertydamage.

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Components and special tools required

Special equipment/materials required for assembly

Sealants, lubricants and adhesives supplied with boiler (in hardware box)

Boiler components and shipping information

1. One quart 30-wt motor oil

2. Rubber and leather gloves

3. Rubber or leather mallet

4. Two 2”x4”x12” boards (used for cushioning when seating push nipples)

5. Two 18-inch pipe wrenches

6. Torque wrench (at least 30 foot-pound capacity)

7. Deep socket, 11/16” for use with torque wrench

8. Standard hand tools, wire, nuts, electrical hand tools

9. 2”x2” steel square stock x 6 inches long, for driving square-socket pipe plugs (supplied with boiler in hardware box)

Usegloveswhenworkingwiththeseproductsasspecifiedintheseinstructionsandintheproductinstructions.

1. Silicone RTV-6500 HiTemp: (3) 10-oz caulk tubes (for sealing between sections)

2. Loc-Tite 30557 pipe dope: (1) 16-oz can (for water and gas piping connections)

3. Hercules Pro Dope: (1) 8-oz jar (for

mixing with 30-wt motor oil, used as lubricant for push nipples)

4. Res Bond 2300: (1) 11-oz caulk tube (for sealing burner assembly)

5. Fast-Tack 87: (1) 13-oz spray can (for securing flue baffles to sections)

Skid 1

Cast iron sections (front, rear and intermediate)

Push nipples

3” x 8” supply nipple and return nipple

Pipe plugs

Draw rods and hardware

All-thread rods (7/8”) and cast-iron draw-up plates for assembling boiler block

Ceramic flue baffles

Hardware box (bolts, nuts, etc., indi-vidually packed/labeled by usage)

Skid 2

Base

Burner kit

Ceramic combustion chamber

Drain pan (with inspection cover plate pre-attached)

Upper casting

4” x 6” boards for section assembly

Skid 3

Jacket components

Jacket insulation

Blower and filter box assembly

Control box assembly

Gas train assembly

Gas train shroud

Components box (igniter, sight glass, supply and return sensors, LWCO assembly, etc.)

Flue adapter assembly

Condensate trap assembly

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Step 1 Place 4x6 boards on base

Ignorethepaletteundertheboilerinthemanualimages—itisleftinplaceduringassemblyfordemonstrationpurposesonly.

1. Remove base from skid.

2. Place a 4x6 board (supplied) against each side as a runner shown.

3. Space runner boards with about even amounts off of each end of the base.

4. The runner boards will be used to support the boiler block during as-sembly, then removed afterward.

Step 2 Oil top surface of runner boards

1. Use a brush to spread 30-wt motor oil on the runner boards. This will allow sections to move easily during draw-up.

Step 3 Position the rear section

Useleathergloveswhenlift-ingormovingboilersections.Sectionsareheavyandcancauseseverepersonalinjuryordeathifmishandled.

Liftsectionusingtwopeople,followingtherecommendationsshowninStep 13, page 8.

1. Identify the rear section — its lower nipple port is on the right side when looking at the inside of the section, as in this photo.

2. Slide the rear section to the end of the base. Have someone support the section during the next step.

Step 4 Bolt rear section to base

1. Use 3/8 x 3½” bolts, wedges, split lock washer and nut on each side as shown.

2. Point the wedge narrow edge toward the section.

Tightenboltfirmly,butDONOTover-tighten—thecastironflangecouldbebro-keniftootight.Tightenonlyuntilthesplitlockwasherhasjustflattened.

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Step 5 Prepare section for baffle

Useofanapproveddustrespiratorisstronglyrecom-mendedwhenhandlingtheinsulatingcomponentsoftheboiler.

1. Spray cast iron heat pin section liber-ally with spray adhesive supplied with the boiler.

2. Avoid spraying on the nipple port machined surfaces.

Step 6 Install baffle

Donotusebafflesiftheyhavebeenbroken,cracked,foldedorfrayed.Obtainre-placementsbeforeproceed-ingwiththeboilerassembly.

1. Place a baffle in the heat pin area of the front section as shown.

2. The cut-off corner must go to the lower right.

3. Press into place.

4. Make sure the baffle does NOT overlap onto the perimeter surfaces of the section. This would prevent the section from drawing up correctly.

Step 7 Apply RTV to perimeter

Rubberglovesarerecom-mendedforthisprocedure.

1. Apply a bead of silicone RTV (sup-plied with boiler) on the perimeter surfaces of the section and around the INSIDE edges of the nipple ports.

2. This is necessary to form a seal be-tween the sections. The seal prevents flue gases from escaping.

3. Extend the bead all the way from the top of the section to the bottom.

4. Keep the bead of silicone close to the INSIDE edge of the nipple ports.

5. This will protect the machined nipple port surfaces from condensation that may occur in the flueways.

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Step 8 Push nipple lubricant


1. In a disposable container, mix some 30-wt motor oil with some of the Hercules Pro Dope supplied with the boiler.

2. The consistency should be similar to thick paint and should flow easily.

3. You will need enough to lubricate all nipple ports and all push nipples — probably about ½ pint is enough.

Step 9 Lubricate nipple ports

1. Brush the pipe dope/oil mixture on the inner machined surfaces of the nipple ports.

2. Avoid getting lubricant on the sili-cone RTV or on the face of the nipple ports.

Step 10 Lubricate push nipples

1. Brush the entire outside surface of each nipple port with the lubricant.

Step 11 Insert push nipples

Avoidscarringordamagingthepushnippleornippleportsurfaces.Thepushnip-plemakesametal-to-metalsealwiththenippleport.Anysurfacedefectscouldcausealeak.

1. Insert a push nipple into each of the two nipple ports.

2. Seat each nipple firmly but squarely.

3. Make sure the nipple face is parallel to the section surface as closely as possible.

4. DO NOT attempt to assemble sec-tions if any nipple port is mis-aligned.

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Step 12 Seat the push nipples

1. Place a 2x4 board across the nipple and strike firmly with a mallet.

2. Do this with several strokes, just so the push nipple is firmly started.

3. Make sure the board is parallel to the nipple port surface to prevent rolling the push nipple.

Step 13 Lifting the sections

Useleathergloveswhenlift-ingormovingboilersections.Sectionsareheavyandcancauseseverepersonalinjuryordeathifmishandled.

Liftsectionusingtwopeople,followingtherecommendationsshowninStep 13, page 8.

1. Lift section, with each person holding at the bottom of the section.

2. Handlers should lift with their legs to avoid back strain.

Step 14 Draw up sections

1. Carefully slide the first intermediate section up to the front.

2. Before pulling the intermediate section up fully, brush lubricant on the inside machined surfaces of the nipple ports as in Step 9, page 7.

3. Use a 2x4 board and mallet to start the section in place as shown in Step 17, page 9.

4. Wipe a small amount of motor oil on the ¾-inch all-thread rods supplied with the boiler to make pull-up easier.

5. Place a ¾” nut and washer plus a cast iron plate (supplied with boiler) on the ¾” rod on each side as shown.

6. Snug finger tight.

Step 15 Pull sections together

1. Use box wrenches (preferred) to pull the sections together.

2. Alternate from one side to the other during pull-up to avoid cocking the nipple ports.

3. When the sections are properly pulled up, they will be nearly metal-to-metal.

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Step 16 Install baffle

Donotusebafflesiftheyhavebeenbroken,cracked,foldedorfrayed.Obtainre-placementsbeforeproceed-ingwiththeboilerassembly.

1. Before adding additional sections, install a baffle in the flueway as in Step 5, page 6 and Step 6, page 6.

2. Place a baffle in the heat pin area of the front section as shown.

3. The cut-off corner must go to the lower right.

4. Press into place.

5. Make sure the baffle does NOT overlap onto the perimeter surfaces of the section. This would prevent the section from drawing up correctly.

Step 17 Use 2x4 and mallet

1. To initially seat the push nipple into the next section, rap with a mallet and 2x4 at each nipple port.

2. Repeat, alternating from right nipple port to left to avoid cocking the push nipples.

Step 18 Install draw rods

ThedrawrodsARENOTusedtopullthesectionstogether,onlytokeepthemfirmlyinposition.

1. When the section assembly is com-pleted, slide a draw rod through each of the four draw rod holes.

2. Apply a washer and nut on each end and pull up finger tight.

Step 19 Use a torque wrench

DONOTexceed30 foot-poundswhentighteningnuts.Highertorquecouldcausebreakageofthecastiron.

1. Use a torque wrench to tighten the nuts on the draw rods.

2. Start with the upper left corner rod first.

3. Tighten the nut to 15 foot-pounds.

4. Move to the lower right rod. Tighten the nut to 15 foot-pounds.

5. Repeat with the lower left, then the upper right rod, both tightened to 15 foot pounds.

6. Repeat this sequence again, but finish the tightening to 30 foot-pounds for each nut.

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Step 20 Bolt boiler to base

Beforeboltingtheboilertothebase,knockthetwo4x6boardsoutfromundertheblock.Ifnecessary,loosenthetwoboltsthatsecurethebacksectiontothebase.

1. Install a bolt, wedge, washer and nut on side of the front section as done in Step 4, page 5.

2. Tighten only until the split lock washer has just flattened.

3. Make sure the back section bolts are tightened as well.

Step 21 Inspection port plugs

1. Apply pipe dope (supplied with boiler) to plugs (supplied) and install in each of the inspection ports at the lower right side of each section.

Step 22 Prepare condensate pan


Thecondensatedrainpanisshownherewiththeinspectionplateandgasketinstalled.Thiscanbedonebeforeoraftertheconden-satedrainpanisboltedtotheboiler.

1. Use the silicone RTV supplied with the boiler to apply a bead on the condensate pan flange around the complete perimeter.

2. At each of the four corners, apply a bead on the flange where the sheet metal edges meet.

Step 23 Install condensate drain pan

1. This procedure requires two people to do correctly.

2. Guide the condensate drain pan through the front of the base as shown.

3. When in position, lift the pan straight up and hold firmly against the bot-tom of the section assembly.

4. Install each bolt with two flat washers, one split lock washer and nut (pro-vided). Insert the bolts from the top.

5. Tighten just until the split lock washer has flattened.

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Step 24 Install condensate drain connector

Thecondensatedrainpanisshownherewithouttheinspectionplateandgasketinstalled,tobeinstalledinStep 25, page 11.

SeeStep 25, page 11fordetailsofcondensatedrainpancomponents.

1. The condensate drain connector con-sists of a plate, O-ring and strainer.

2. Assemble the three parts as shown.

3. Insert the assembly into the bottom of the condensate drain pan.

4. Look for underneath while assem-bling to ensure the condensate drain connector is properly seated.

5. Secure in place with the screws provided.

Step 25 Install inspection cover

Thiscouldbedonebeforethecondensatedrainpanisinstalled,asshowninStep 22, page 10.

Theinspectioncoverisusedforannualinspectionofthesectionassemblyandcondensatehandlingcompo-nents.

1. Assemble inspection cover flange and gasket.

2. Position over condensate drain pan inspection opening.

3. Secure with screws provided.

LEGEND for drawing at right:

30 Hex nuts

31 Inspection cover

32 Inspection cover gasket

33 Condensate drain pan

34 Condensate strainer

35 Condensate drain connector O-ring

36 Condensate drain connector plate

37 Washers

38 Hex bolts

Step 26 Inspect combustion chamber area for excess silicone

1. Remove any excess silicone that may have extruded into the interior of the section assembly.

2. This area must not have any blockage where the combustion chamber will be inserted.

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Step 27 Install combustion cham-ber

Thecombustionchambermaterialisfragile,andcanbecrackedorgougedwithin-correcthandling.HANDLECAREFULLY!DONOTusethechamberifitisdam-aged.


1. Insert the chamber into the top of the section assembly as shown.

2. Position the chamber with the ROUND hole toward the front and the SQUARE hole to the rear.

3. The combustion chamber should sit evenly in the opening, with its FLAT surface facing up and even with the surface of the sections.

Step 28 Position the burner gasket


1. Carefully place the burner gasket on the surface of the combustion chamber.

Step 29 Apply Resbond adhesive to the burner gasket


1. Apply a generous bead of Resbond adhesive (supplied with boiler) around the entire burner gasket.

2. Position the bead in the center of the gasket.

3. This adhesive will bond the gasket to the burner when the burner is installed.

13P/N 42-9551


Step 30 Burner and manifold

REMOVETHEPILOTORIFICEASSEMBLYbeforeproceeding.Thepilotorificeassembly(showninStep 37, page 15)isfactory-installedinthemanifold.Itmustberemovedbeforethemanifoldisinstalledtopreventdamagetothepilotassemblyorpilottube.

1. This illustration shows the manifold (left) and the burner (right).

2. Orient the burner as shown, with the double set of bolt notches on the same side as the blower flange of the manifold.

3. This will position the pilot tube at the top as shown in the lower photo.

Step 31 Apply silicone RTV to top surface of section assembly


1. Apply a generous bead of silicone RTV completely around the flange surface of the section assembly.

Step 32 Mark bolt locations

1. Some of the bolt notches in the burner flange will be used to secure the manifold.

2. The burner is attached to the section assembly before the manifold. To avoid using the wrong bolt notches, place the burner against the manifold as shown.

3. Use a marker pen to mark ONLY the bolt notches NOT required for bolting the manifold.

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Step 33 Install the burner

1. Place the burner on top of the section assembly as shown.

2. The PILOT TUBE must be at the REAR of the boiler.

Step 34 Install burner bolts

1. Press the burner flange down firmly and install bolts, washers and nuts supplied.

2. Place bolts ONLY at the bolt notches marked in Step 32, page 13.

3. Secure the bolts firmly, but avoid distorting the burner flange.

Step 35 Position the manifold

1. Place the manifold on top of the section assembly as shown, with the blower flange to the FRONT of the boiler.

Step 36 Install manifold bolts

1. The manifold gasket is pre-attached to the manifold at the factory.

2. Install a bolt, two flat washers, split lock washer and nut at each bolt lug on the manifold.

3. Tighten the bolts only until the split lock washer is just flattened.

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Step 37 Install pilot assembly

1. Use a flashlight to look down through the pilot mounting hole at the top rear of the manifold.

2. The pilot tube (shown in Step 34, page 14 at the top rear of the burner) must be aligned with the hole in the manifold.

3. If the pilot tube is not aligned, use a screwdriver to reach into the mani-fold hole and coax the pilot tube into position.

4. After ensuring the pilot tube is aligned properly, insert the pilot orifice assembly as shown.

5. Screw the pilot orifice into the manifold hole securely. DO NOT over-tighten.

Step 38 Install burner inspection port

1. The burner inspection port consists of a plate, gasket, inspection glass, and another gasket.

2. Place against the mounting boss on the top front section.

3. Secure with the bolts and washers provided.

Step 39 Install plug in front sec-tion lower nipple port tapping

1. Obtain the 3” flat plug supplied with the boiler.

2. Apply pipe dope to the tapping and the plug.

3. Install the plug securely.

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Step 40 Apply jacket front insula-tion

Leatherglovesarerecom-mendedwhenhandlingsheetmetalcomponents.Theywillreducethepossibilityofcutsfromsheetmetaledges.

1. Press jacket front insulation against the back of the front panel.

Step 41 Mounting hole alignment

1. The installer is pointing to the jacket panel mounting hole toward the left center of the jacket front panel.

2. Insert a screwdriver through this hole and the insulation to help align the hole to the mounting boss on the front section while placing the jacket front panel.

3. Position the jacket front panel on the section and secure with a bolt through this hole.

Step 42 Install gas line bracket

1. Install the gas line bracket to the right front using the bolts provided.

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Step 43 Apply jacket rear insula-tion


1. Press jacket rear insulation against the back of the rear panel.

Step 44 Install jacket rear panel

Thejacketrearpanelissup-pliedwiththeigniterandconduitboxinstalled.


1. Insert a screwdriver through the left center jacket mounting hole.

2. Use the screwdriver to help align the mounting hole with the mounting boss on the rear section.

3. Secure the jacket rear with the bolts provided.

4. Apply the upper left bolt and the two lower bolts.

5. The fourth jacket mounting hole is under the conduit box. Temporarily remove this box to install the bolt. Then re-install the box.

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Step 45 Install flue adapter

MakesuretheflueadaptercondensatenippleislocatedattheBOTTOMwhenin-stalled.


1. Apply silicone RTV to the flue adapter mounting boss.

2. Position the flue adapter on the boss and insert the four mounting bolts. The condensate nipple must be pointed DOWN.

Step 46 Install supply nipple

Theboilerissuppliedwithtwonipplesthatincludethreecontroltappings.Thenipplesareidentical,buttheymustbepositioneddiffer-ently.

1. Apply pipe dope to one of the 3-inch nipples and the upper right tapping on the rear of the boiler.

2. Install the supply nipple in the tap-ping.

3. When the nipple is tightened, it must be in the orientation shown — the ½” tapping must be on top, with a ¾” tapping at the right and at the bottom.

4. The ½” tapping is used for the 10K supply sensor.

Step 47 Install supply nipple

Theboilerissuppliedwithtwonipplesthatincludethreecontroltappings.Thenipplesareidentical,buttheymustbepositioneddiffer-ently.

1. Apply pipe dope to one of the other 3-inch nipple and the lower left tap-ping on the rear of the boiler.

2. Install the return nipple in the tap-ping.

3. When the nipple is tightened, it must be in the orientation shown — the ½” tapping must be on right, with a ¾” tapping at the bottom and at the left side.

4. The ½” tapping is used for the 10K return sensor.

5. The ¾” bottom tapping is used for the boiler drain.

6. The ¾” side tapping should be plugged unless used for a special purpose.

19P/N 42-9551


Step 48 Install the ignition elec-trode assembly

Check/adjusttheigniterelectrodepositioningbeforeinstalling.Theyarenotfac-torypreset.

1. Check the distance from the ignition electrode plate to the front end of the ignition electrode ceramics. It must be 1½ inches (see dimension “A” in drawing at right.

2. Check the spacing between the igniter tips. It must be 1/8 inch (see drawing at right).

3. If the electrodes are not positioned correctly, loosen the mounting screws and adjust.

4. Apply the gasket to the back of the ignition electrode plate.

5. Bolt the plate to the boiler.

6. Attach the electrode wires to the electrodes. Then slide the rubber boots over the connections.

Step 49 Attach the UV scanner

1. Attach the UV scanner to the threaded boss on the electrode plate assembly.

Step 50 Mark the gas line nipple

Thegaslinenippleisfactory-attachedtothemountingbrackets.Thenipplemustberemovedforconnectiontothegastrain.Thisstepen-suresthenippleiscorrectlyplacedwhenre-attachedtothebracket.

1. Use a marker pen to mark the loca-tion of the two mounting clamps on the gas line nipple.

2. Mark the gas line nipple to indicate which end is the top.

20 P/N 42-9551


Step 51 Mount the control panel

Thecontrolpanelmountsonthemountingclipatthetopofthejacketfrontpanel.Theconduitfittingandthesensorhosemustberoutedthroughjacketpanel.

1. BX conduit fitting — Hold the control panel close enough to the jacket front panel to allow inserting the conduit fitting through the back of the panel. Then apply and tighten the fitting lock nut.

2. Feed the sensor hose through the grommet-fitted hole in the jacket panel (see second photo).

3. Then clip the control panel to the mounting bracket.

Step 52 Attach the gas line nipple to the gas train

1. Apply pipe dope to the gas line nipple bottom end. REMOVE any pipe dope from the inside of the pipe.

Step 53 Tighten gas line nipple

Usetwowrenchestopreventdamagetogastraincompo-nents.

1. Use two pipe wrenches to tighten the gas line nipple connection.

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Step 54 Mount the gas train

1. Attach the gas train to the front of the boiler using the bolts supplied.

Step 55 Re-attach gas line nipple brackets

1. Re-attach the gas line nipple mount-ing brackets, but leave loose. The gas line will have to be manipulated in a following step.

2. Loosen the U-clamp on the gas train to allow the gas train to be rotated as the gas line nipple is pulled forward in a later step.

Step 56 Apply blower flange gasket

1. Remove the protective backing from the blower flange gasket to expose the adhesive.

2. Place carefully on the blower flange and press in place.

Step 57 Install gas line grommet in air box

1. Install the gas line grommet provided into the gas line opening on the bot-tom of the air box.

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Step 58 Move the air box/blower assembly into position

1. This procedure requires two people.

2. Move the air box/blower assembly into position.

3. Guide the gas line into the grommet-fitteded opening in the bottom of the air box.

Step 59 Attach the air box/blower assembly to the manifold blower flange 1. Use the nuts provided to secure the

assembly to the manifold blower flange.

Step 60 Tighten gas line nipple clamps and gas train clamp

1. Securely tighten the gas line nipple clamps.

2. Tighten the gas train U-clamp.

Step 61 Connect air box pressure switch sensing tube

1. Remove the air pressure sensing tube from the air box.

2. The air box pressure switch is mounted on the lower center of the jacket front panel.

3. Connect the tube to the air pressure switch and to the hose barb on the bottom of the air box.

23P/N 42-9551


Step 62 Install gas valve by-pass line

De-burrthealuminumtub-ingaftercuttingtoensuretheendsarenotobstructed.

1. Connect an aluminum tube (sup-plied with boiler, but cut to length during installation) from the gas valve by-pass outlet port to the gas valve by-pass inlet port (rear of valve).

Step 63 Connect gas valve air box sensor line


1. Connect an aluminum tube to the bottom of the gas valve (PL-AIR tap-ping).

2. Connect the other end of the tubing to the brass fitting on the bottom of the air box.

Step 64 Connect pilot gas line


1. The pilot gas line aluminum tube must connect from the pilot gas valve on the front of the boiler to the pilot orifice assembly on the top of the manifold (top rear).

2. Cut the tube with extra slack to en-sure it will be long enough after the jacket side panel is installed.

3. Route the tubing through the hole in the front jacket panel.

4. Connect the tubing to the pilot gas valve (at front of boiler).

5. Leave the other end of the tube loose.

Step 65 Apply right side jacket insulation


1. Press the right side insulation into place.

2. Make sure to position the insulation UNDER the pilot gas line tubing.

3. Cut the pilot gas tubing if necessary, then attach to the pilot orifice assem-bly at the top rear of the manifold.

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Step 66 Install jacket right side panel


1. Secure the jacket right side panel in place using the screws provided.

2. Position the pilot gas tubing in the slot located in the top right end of the jacket right side panel.

Step 67 Install jacket top left panel


1. Mount the jacket top left panel to the boiler using the screws provided.

2. The openings in this panel are used to install controls in the boiler top left tappings.

Step 68 Mount controls in top left tappings

1. There are 11 tappings in the top left — 1¼-inch tappings at the front and rear of the boiler — the (9) tappings in between are all 1 inch.

2. Rear tapping — install the boiler relief valve.

3. Second tapping from the rear — mount the manual reset limit control.

4. Third tapping from the rear — mount the automatic air vent.

5. Sixth tapping from rear — mount the remote low water cutoff probe and J-box.

6. Front tapping — mount the pressure/temperature gauge.

7. All other tappings — install 1-inch plugs.

Step 69 Install left side junction box

1. Connect the three BX conduits (from the front, top and rear of the boiler) to the left side junction box, provided.

2. The wires are both color-coded and numbered.

3. Connect the wires together, matching color/number.

4. Install the junction box cover.

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Step 70 Route plastic sense line through jacket rear

1. Disconnect the rear conduit junction box before proceeding.

2. Guide the plastic sense line through the grommeted hole in the jacket rear panel.

3. Re-attach the rear conduit junction box.

Step 71 Apply left side jacket insulation


1. Press the left side insulation into place.

2. Make sure to position the insulation UNDER the conduits and the plastic sense line.

Step 72 Install jacket left side panel


1. Install and secure the jacket left side panel using the screws provided.

Step 73 Install top jacket panel strips


1. Install a jacket top panel strip on each side of the jacket top.

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Step 74 Connect wires to air box components

Seethewiringdiagrams,Figure 1, page 28 and Fig-ure 2, page 30fordetailedinformation.

1. Connect the wires from the air pres-sure switch and relief valve switch to the control panel.

2. See callout 3 in schematic wiring diagram, Figure 1, page 28.

Step 75 Connect wires to air box components


1. Connect wires from remote LWCO, gas valve molex, LGPS and pilot gas valve.

2. See callouts 1, 2, 4, 5 and 6 in schematic wiring diagram, Fig-ure 1, page 28.

Step 76 Connect motor wires


1. Attach the BX conduit fitting on the motor conduit to the top of the control panel.

2. Connect the wires to the matching color coded/numbered wires in the control panel.

3. See callout 7 in schematic wiring diagram, Figure 1, page 28.

Step 77 Install the air filter

1. Place the air filter in the air box as shown.

2. The left top edge of the filter must go against the inside left of the air box.

3. The bottom right of the filter goes against the bottom right of the air box.

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Step 78 Install the air box cover

TheairboxcoverMUSTbeinplaceduringboileropera-tion.

1. Attach the air box cover using the screws provided.

Step 79 Install the air gas train shroud

1. Attach the gas train shroud to the jacket front using the hardware provided.

Step 80 Follow Boiler Installation and Operating Instructions manual and HeatNet Control manual

1. Follow all instructions in both of the manuals listed. Pipe and wire the boiler accordingly.

2. Perform the tests indicated in the manuals.

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1

2

3

4

6

5

7

Figure 1 Schematic wiring diagram (numbered bullets show locations of wiring field connections (all wires color coded and numbered)

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1

2

3

4

6

5

7

Figure 1 (Continued)

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Figure 2 Ladder wiring diagram

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Figure 2 (Continued)

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Documents

Hydrotherm KN - mesteksa.commesteksa.com/fileuploads/Literature/Hydrotherm... · support the boiler block during as-sembly, then removed afterward. Step 2 Oil top surface of runner