HydroTherm KN-6, KN-10, KN-20 Installation & Operating Instructions Manual

KN SERIES GAS BOILER
WITH CONTROL
INSTALLATION & OPERATING
INSTRUCTIONS
IOMKN2-508
MEA #444-05-E MASS Plumbers #G1-06-04-28
DESIGNED AND TESTED ACCORDING TO A.S.M.E. BOILER AND PRESSURE VESSEL CODE, SECTION IV FOR A MAXIMUM ALLOWABLE WORKING PRESSURE OF 100 PSI, 700 kPa, WATER.
WARNING: If the information in this manual is not followed exactly, a fi re or explosion may result causing property damage, personal injury or loss of life.
Do not store or use gasoline or other fl ammable vapors and liquids in the vicinity of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch. Do not use any phone in your building.
• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.
• If you cannot reach your gas supplier, call the fi re department.
Installation and service must be performed by a qualifi ed installer, service agency or the gas supplier.
CAUTION: Do not use automotive anti-freeze in the boiler waterways. If the use of antifreeze is necessary an anti-freeze specifi cally formulated for hydronic heating systems must be used or damage to the boiler may occur voiding the warranty!
INSTALLER, THESE INSTRUCTIONS TO BE AFFIXED ADJACENT TO THE BOILER / WATER HEATER.
Advanced Thermal Hydronics
IN UNITED STATES: 260 NORTH ELM ST. • WESTFIELD, MA 01085 • (413) 564-5515 • FAX (413) 568-9613
IN CANADA: 7555 TRANMERE DRIVE • MISSISSAUGA, ONT. L5S 1L4 • (905) 672-2991 • FAX (905) 672-2883
www.hydrothermkn.com
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KN INSTALLATION AND OPERATION INSTRUCTIONS
AVERTISSMENT. 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 infl ammables à proximité de cet appareil ou de tout autre appareil.
QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ:
• Ne pas tenter d’allumer d’appareil.
• Ne touchez à aucun interrupteur; ne pas vous servir des téléphones se trouvant dans le bâtiment.
• 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 qualifi é ou par le fournisseur 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 13
General Piping Requirements ..........................page 14
Heating System Piping .....................................page 14
Domestic Water Supply Piping .........................page 17
Condensate Piping ...........................................page 18
Gas Supply Piping ............................................page 19
Electrical Wiring ................................................ page 20
Boiler Operation ................................................page 20
Operating Instructions ......................................page 21
Sequence of Operation .....................................page 23
Ignition Troubleshooting ....................................page 24
Checking & Adjustment ....................................page 26
Diagnostics ....................................................... page 27
Maintenance ..................................................... page 28
Troubleshooting ................................................page 29
Repair Parts ......................................................page 30
Wiring ...............................................................page 33
Warranty ...........................................................page 36
BEFORE YOU START
This manual covers the application, installation, operation and maintenance of a KN series boiler.
To obtain the safe, dependable, effi cient operation and long life for which this boiler was designed, these instructions must be read, understood and followed.
The KN boiler series has been design certifi ed by CSA for use with natural gas under the latest revision of ANSI-Z21.13/CSA 4.9, Gas-Fired Hot Water Boilers and CAN1-3.1, Industrial and Commercial Gas Fired Packaged Boilers. Each unit has been constructed and hydrostatically tested for a maximum working pressure of 100 psi, 700 kPa, in accordance with Section IV of the A.S.M.E. Boiler and Pressure Vessel Code.
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 HydroTherm’s instruction sheet MACODE-3. Please refer to the back of this manual for required regulations.
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.
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 HydroTherm distributor or contact the HydroTherm Customer Service Department at: 260 North Elm Street, Westfi eld, MA 01085. Always include the model and serial numbers from the rating
plate of the boiler in question.
KN INSTALLATION AND OPERATION INSTRUCTIONS
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RATINGS & CAPACITIES
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
1. This boiler is suitable for indoor installations only. 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.
NOTE: Service clearances are not mandatory, but are recommended to ensure ease of service should it be required.
Table 1 - Clearances
Clearance to Service Combustibles Clearance in mm in mm Top 6 153 24 610 Back 6 153 24 610 Left Side 6 153 6 152 Right Side 6 153 6 152 Front 6 153 36 914 Flue 6 153
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 unless the combustion air is piped from the outside, see the COMBUSTION AIR & VENTILATION section.
6. NEVER place this boiler in a location that would subject it to temperatures at or near freezing.
WARNING: Never store combustible materials, gasoline or any product containing fl ammable 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!
COMBUSTION AIR & VENTILATION
WARNING: This boiler must be supplied with combustion air in accordance with Section 5.3, 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/water heater can result in excessive levels of carbon monoxide which can result in severe personal injury or death!
2. An optimum site will be level, central to the piping system, close to a chimney or outside wall and have 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 moisture during operation or servicing.
3. Ensure that the fl oor is structurally sound and will support the weight of the boiler.
NOTE: The KN may be installed directly on combustible fl ooring, 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.
To operate properly and safely this boiler requires a continuous supply of air for combustion. NEVER store objects on or around the boiler!
CAUTION: Combustion air contaminated with fl uoro­carbons 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!
CAUTION: 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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KN INSTALLATION AND OPERATION INSTRUCTIONS
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 fi replace, 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.
WARNING: Never operate the KN in an environ­ment subjected to a negative pressure unless it is Direct Vented. 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 confi ned space the minimum clearances listed in Table 1 must be maintained between it and any combustible construction. When installed in a confi ned 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 suffi cient volume to meet the criteria for an unconfi ned space. The total air requirements of all gas utilization equipment, fi replaces, 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 confi ned 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 confi ned 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 in
2
/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 cross­sectional area as the free area of the opening to which they connect.
Table 2 - Make-up Air Duct Sizing
Required Cross Sectional Duct Area
Input 1/4 in, 6.4 mm Metal Wooden (MBH)
Wire Screen Louvers Louvers
in2 cm2 in2 cm2 in2 cm2 600 150 967 200 1292 600 3869 1000 250 1612 334 2154 1000 6448 2000 500 3224 668 4308 2000 12,896
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 above.
Direct Intake Air Option - General
This confi guration 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 1, 2, 3 & 4. It must be sized per Table 3.
Single wall galvanized smoke pipe, single wall aluminum pipe, fl exible aluminum pipe, PVC or CPVC pipe can be used for the intake air pipe.
Table 3 - Intake Air Pipe Sizing
Model Pipe Diameter Size in2 mm2 600 5 127 1000 6 152 2000 9 229
NOTE: 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.
KN INSTALLATION AND OPERATION INSTRUCTIONS
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Direct Intake Air Option - Vertical
The maximum equivalent length for the vertical intake air pipe is 80 ft, 19.7 m. 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 3. The penetration point in the roof must be properly fl ashed and sealed. Approved caps are listed in Table 4.
Direct Intake Air Option - Horizontal
The maximum equivalent length for the horizontal intake air pipe is 80 ft, 19.7 m. 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.
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 1, 2 or 4. Approved terminals are listed in Table 5.
Table 4 - Vertical Intake & Vent System Components
Company Description Part Number Dia., in Flex-L 5 Flex-L 6 Flex-L 9 Heat Fab Rain Cap 5500CI 5 Heat Fab Rain Cap 5600CI 6 Heat Fab Rain Cap 51000CI 9 Pro Tech Rain Cap FSRC5 5 Pro Tech Rain Cap FSRC6 6 Pro Tech Rain Cap FSRC10 9 Z Flex 5 Z Flex 6 Z Flex 9
Table 5 - Horizontal Intake & Vent System Components
Company Description Part Number Dia., in Flex-L Vent Adapter 5 Flex-L Vent Adapter 6 Flex-L Vent Adapter 9 Termination T Termination T Termination T Termination EL Termination EL Termination EL Heat Fab Vent Adapter 9501KN10 5 Heat Fab Vent Adapter 9601KN10 6 Heat Fab Vent Adapter 91001KN10 9 Termination T 9590TEE 5 Termination T 9690TEE 6 Termination T 90990TEE 9 Termination EL 7514TERM 5 Termination EL 9614TERM 6 Termination EL 90914TERM 9 Pro Tech Vent Adapter 5 Pro Tech Vent Adapter FSA-HFAG 6 Pro Tech Vent Adapter 9 Termination T 300313 5 Termination T 300314 6 Termination T 9 Termination EL 5 Termination EL 6 Termination EL 9 Z Flex Vent Adapter 5 Vent Adapter 6 Vent Adapter 9 Termination T 02SVSTTX05 5 Termination T 6 Termination T 9 Termination EL 5 Termination EL 6 Termination EL 9
GENERAL VENTING GUIDELINES
WARNING: The vent installation must be in accordance with Part 7, Venting of Equipment, of the National Fuel Gas Code, ANSI Z223.1/NFPA 54-latest revision or applicable provisions of the local building codes. Canadian installations must comply with CSA B149.1 or .2 Installation Code. Improper venting can result in excessive levels of carbon monoxide which can result in severe personal injury or death!
All vent systems must be fully supported by the building structure and not by the boiler. Appropriate thimbles and fi re-stops must be used where required.
WARNING: Common positive pressure vent systems are not to be used! Improper installation can result in excessive levels of carbon monoxide which can cause severe personal injury or death!
NOTE: A single acting barometric damper must be installed in the vent connector if a vertical vent system produces a negative draft in excess of 0.2 in,
5.08 mm W.C at the fl ue outlet.
NOTE: One of the vent system adapters listed in Table 5 must be attached to the fl ue outlet of the boiler before the vent system is connected.
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KN INSTALLATION AND OPERATION INSTRUCTIONS
VENT SYSTEM OPTIONS
The KN may be vented the following ways:
1) Direct Vent - Positive Pressure, Category IV uses a vent system certifi ed to UL 1738 for installations in the United States, ULS636 for installations in Canada. Combustion air is piped from the outdoors to the blower inlet.
2) Side Wall Vent - Positive Pressure, Category IV uses a stainless steel vent system certifi ed to UL 1738 for installations in the United States, ULS636 for installations in Canada. Combustion air is obtained from the space in which the unit is installed.
3) Vertical Vent - Positive Pressure, Category IV uses a stainless steel vent system certifi ed to UL 1738 for installations in the United States, ULS636 for installations in Canada. Combustion air is obtained from the space in which the unit is installed.
4) Vertical Vent - Negative Pressure, Category II uses an approved metal chimney system. Combustion air is obtained from the space in which the unit is installed.
DIRECT VENT POSITIVE PRESSURE, CATEGORY IV
In this confi guration 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! The vent system must be sized per Table 6.
Table 6 - Direct Vent Pipe Size, Positive Pressure
Model Pipe Diameter Size in 600 5 127 1000 6 152 2000 9 229
Horizontal Direct Vent Systems - Figures 1 & 2
The vent materials used in positive pressure vent systems must be certifi ed to UL 1738 for installations in the United States, ULC S636 for installations in Canada. The vent terminals listed in Table 5 must also be used. Below is a list of some of the manufactures that have systems that meet these requirements. Others manufacturers that have UL certifi ed systems may be used.
2
mm2
Heat-Fab, Inc. 38 Hayward Street Greenfi eld, MA 01301, (800) 772-0739.
Z-Flex U.S., Inc. 20 Commerce Park North, Bedford, NH 03110-6911, (800) 654-5600.
Protech Systems Inc. 26 Gansevoort Street Albany, NY 12202 (518) 463-7284
The maximum equivalent length for the horizontal vent pipe is 80 ft, 19.7 m. Each 90° elbow and the vent terminal are equal to 10 ft, 3.3 m of straight pipe. 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. The vent system must be pitched down, toward the vent terminal, 1/4 in/ft, 21mm/m. 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.
Avoid terminal locations likely to be affected by winds, snowdrifts, people and pets. Protect building materials and vegetation from degradation caused by the fl ue gases.
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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 3
The vent materials used in positive pressure vent systems must be certifi ed to UL 1738 for installations in the United States, ULC S636 for installations in Canada.
The vent terminals listed in Table 4 must also be used. Below is a list of some of the manufactures that have systems that meet these requirements. Others manu­facturers that have UL certifi ed systems may be used.
Heat-Fab, Inc. 38 Hayward Street Greenfi eld, MA 01301, (800) 772-0739.
Z-Flex U.S., Inc. 20 Commerce Park North, Bedford, NH 03110-6911, (800) 654-5600.
Protech Systems Inc. 26 Gansevoort Street Albany, NY 12202 (518) 463-7284
The maximum equivalent length for the vertical vent pipe is 80 ft, 19.7 m. Each 90° elbow and the intake air cap are equal to 10 ft, 3.3 m of straight pipe. 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 fi re-stops.
The top of a vertical vent system must extend at least
1
5
/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
3. In addition the vent system must conform to the dimensions shown in Figure 3. The penetration point in the roof must be properly fl ashed 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 4
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 4. Also follow the general instructions in the COMBUSTION AIR & VENTILATION and GENERAL VENTING GUIDELINES sections.
KN-6 Multiple Boiler Venting Category II Venting (Negative)
"B"
ALL CONNECTIONS
DOUBLE ACTING
BARAMETRIC DAMPER
THERMAL SPILL
SWITCH
5" AIR INLET
5" FLUE OUTLET
"D"
"A"
BOILER #5
(IF REQUIRED)
BOILER #4
(IF REQUIRED)
TO BE "T-WYE"
BOILER #3
(IF REQUIRED)
BOILER #2
BOILER #1
(ALWAYS LEAD)
"C"
Table 1 - Common Vent Sizes
Table 2 - Vent Lengths
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KN INSTALLATION AND OPERATION INSTRUCTIONS
KN-10 Multiple Boiler Venting Category II Venting (Negative)
ALL CONNECTIONS
DOUBLE ACTING
BARAMETRIC DAMPER
THERMAL SPILL
SWITCH
6" AIR INLET
"A"
"D"
TO BE "T-WYE"
"B"
"C"
Table 1 - Common Vent Sizes
6" FLUE OUTLET
BOILER #5
(IF REQUIRED)
BOILER #4
(IF REQUIRED)
BOILER #3
(IF REQUIRED)
BOILER #2
KN-20 Multiple Boiler Venting Category II Venting (Negative)
"B"
ALL CONNECTIONS
TO BE "T-WYE"
THERMAL SPILL
SWITCH
DOUBLE ACTING
BARAMETRIC DAMPER
"D"
"A"
BOILER #1
(ALWAYS LEAD)
Table 2 - Vent Lengths
"C"
9" AIR INLET
9" FLUE OUTLET
BOILER #4
(IF REQUIRED)
(IF REQUIRED)
Table 1 - Common Vent Sizes
Table 2 - Vent Lengths
BOILER #2BOILER #3
BOILER #1
(ALWAYS LEAD)
KN INSTALLATION AND OPERATION INSTRUCTIONS
Figure 1 - Horizontal Air Intake and Venting for a Single Direct Vent System
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Figure 2 - Horizontal Air Intake and Venting for Multiple Direct Vent Systems
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Figure 3 - Vertical Air Intake and Venting for Direct Vent System
Figure 4 - Combination Direct Vent Systems
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SIDE WALL VENT POSITIVE PRESSURE, CATEGORY IV
In this confi guration the boiler blower is used to push the fl ue products horizontally to the outdoors, see Figure 5.
Figure 5 - Side Wall Venting
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.
VERTICAL VENT POSITIVE PRESSURE - CATEGORY IV
In this confi guration the boiler blower is used to push the fl ue products vertically to the outdoors, see Figure
6. 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 6 - Vertical Positive Pressure Venting
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