Hydrotherm KN

Transcription

Hydrotherm KN

Hydrotherm
®
KN
-Series
Gas-fired direct vent
Cast iron boilers
Model KN-20 only
Field assembly
instructions
Also read and follow:
KN Series Gas Boiler
Installation & Operating
Instructions and KN
HeatNet Control Manual
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
this manual and the documents listed above. 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
dust-free 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.
P/N 42-9551 Copyright 2011 Mestek, Inc.
KN Series Gas-fired direct vent cast iron boilers – Field assembly instructions
Contents and information
Read before beginning the installation . . . . . . . . 5
Boiler ratings and specifications . . . . . . . . . . . . 6
Installation site preparation . . . . . . . . . . . . . . . 7
Hazard icons
You will find the following icons
throughout this manual.
(English/French)
Prepare the boiler . . . . . . . . . . . . . . . . . . . . . 10
Water piping . . . . . . . . . . . . . . . . . . . . . . . . 11
Gas piping . . . . . . . . . . . . . . . . . . . . . . . . . 18
Wiring a single boiler . . . . . . . . . . . . . . . . . . 20
Control setup . . . . . . . . . . . . . . . . . . . . . . . 25
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.
Vent piping (and air piping when used) . . . . . . . 28
Condensate drain line . . . . . . . . . . . . . . . . . . 29
Fill and test the system . . . . . . . . . . . . . . . . . 30
Starting the boiler . . . . . . . . . . . . . . . . . . . . 32
The NOTICE icon calls out special
instructions that are important, but
are not related to hazards.
Other manuals
Annual start-up . . . . . . . . . . . . . . . . . . . . . . 41
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 42
Replacement parts . . . . . . . . . . . . . . . . . . . . 46
Appendix A — suggested wiring . . . . . . . . . . . 48
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 installation 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.
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P/N 42-9551
Read before proceeding
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.
Codes and standards
Attention:
Code compliances
Use of an approved dust respirator is strongly
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.
Electrical shock hazard — Disconnect all electrical
power sources to the boiler before making any electrical
connections.
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.
recommended when handling the insulating components of the boiler.
Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and dangerous
operation! Verify proper operation after servicing.
Failure to comply with the above could result in severe
personal injury, death or substantial property damage.
Before assembling the boiler . . .
The electrical connections to this boiler must be made in
accordance with all applicable local codes and the latest
revision of the National Electrical Code, ANSI /NFPA-70.
Installation should also conform to CSA C22.1 Canadian
Electrical Code Part I if installed in Canada. Install a separate 120 volt 15 amp circuit for the boiler. A properly rated
shut-off switch should be located at the boiler. The boiler
must be grounded in accordance with the authority having
jurisdiction, or if none, the latest revision of the National
Electrical Code, ANSI/NFPA-70.
Verify boiler rating and gas supply
• Before assembling and installing the boiler, check the ratings to ensure that the unit has been sized properly for the job.
• Ensure that the boiler will be set up for the type of gas available at the
installation site.
Verify location is suitable
• Ensure the availability of an adequate electrical supply, uncontaminated air for combustion, and that vent (and air) piping can be correctly installed.
• Ensure the boiler can be connected to system water piping and gas
supply.
DO NOT open any gas valve, or attempt to fire the boiler,
until all boilers have been set up and verified following the
instructions in the KN Series Gas Boiler Installation &
Operating Instructions.
• The boiler must not be exposed to dripping or spraying water or to
rain.
• If replacing an existing boiler, find out what caused the boiler to fail
before installing a new boiler. Correct the problems that led to failure,
or the failure may happen to the new boiler.
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Line voltage field wiring of any controls or other devices
must use copper conductors with a minimum size of
#14 awg. Use appropriate wiring materials for units
installed outdoors.
Failure to comply could cause a boiler failure, leading to
possible severe personal injury, death or substantial property damage.
3
Components and special tools required
Special equipment/materials required for assembly
1. One quart 30-wt motor oil
5. Two 18-inch pipe wrenches
2. Rubber and leather gloves
6. Torque wrench (at least 30 foot-pound
capacity)
3. Rubber or leather mallet
4. Two 2”x4”x12” boards (used for
cushioning when seating push nipples)
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)
Sealants, lubricants and adhesives supplied with boiler (in hardware box)
Use gloves when working with
these products as specified in
these instructions and in the
product instructions.
1. Silicone RTV-6500 HiTemp: (3) 10oz 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)
Boiler components and shipping information
Skid 1
Skid 2
Skid 3
Cast iron sections (front, rear and
intermediate)
Base
Jacket components
Burner kit
Jacket insulation
Push nipples
Ceramic combustion chamber
Blower and filter box assembly
3” x 8” supply nipple and return
nipple
Drain pan (with inspection cover
plate pre-attached)
Control box assembly
Pipe plugs
Upper casting
Draw rods and hardware
Gas train shroud
4” x 6” boards for section assembly
Components box (igniter, sight
glass, supply and return sensors,
LWCO assembly, etc.)
All-thread rods (7/8”) and cast-iron
draw-up plates for assembling boiler
block
Ceramic flue baffles
Hardware box (bolts, nuts, etc., individually packed/labeled by usage)
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Gas train assembly
Flue adapter assembly
Condensate trap assembly
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Step 1 Place 4x6 boards on base
Ignore the palette under the
boiler in the manual images
— it is left in place during
assembly for demonstration
purposes only.
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 assembly, 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
Use leather gloves when lifting or moving boiler sections.
Sections are heavy and can
cause severe personal injury
or death if mishandled.
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.
Lift section using two
people, following the
recommendations shown in
Step 13, page 8.
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.
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Tighten bolt firmly, but DO
NOT over-tighten — the
cast iron flange could be broken if too tight. Tighten only
until the split lock washer has
just flattened.
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Step 5 Prepare section for baffle
Use of an approved dust
respirator is strongly recommended when handling the
insulating components of the
boiler.
1. Spray cast iron heat pin section liberally with spray adhesive supplied with
the boiler.
2. Avoid spraying on the nipple port
machined surfaces.
Step 6 Install baffle
Do not use baffles if they
have been broken, cracked,
folded or frayed. Obtain replacements before proceeding with the boiler assembly.
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
Rubber gloves are recommended for this procedure.
1. Apply a bead of silicone RTV (supplied 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 between 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 silicone 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
Avoid scarring or damaging
the push nipple or nipple
port surfaces. The push nipple makes a metal-to-metal
seal with the nipple port. Any
surface defects could cause a
leak.
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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 sections 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
Use leather gloves when lifting or moving boiler sections.
Sections are heavy and can
cause severe personal injury
or death if mishandled.
1. Lift section, with each person holding
at the bottom of the section.
2. Handlers should lift with their legs to
avoid back strain.
Lift section using two
people, following the
recommendations shown in
Step 13, page 8.
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 metalto-metal.
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Step 16 Install baffle
Do not use baffles if they
have been broken, cracked,
folded or frayed. Obtain replacements before proceeding with the boiler assembly.
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
The draw rods ARE NOT
used to pull the sections
together, only to keep them
firmly in position.
1. When the section assembly is completed, 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
DO NOT exceed 30 footpounds when tightening
nuts. Higher torque could
cause breakage of the cast
iron.
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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9
Step 20 Bolt boiler to base
Before bolting the boiler to
the base, knock the two 4x6
boards out from under the
block. If necessary, loosen the
two bolts that secure the back
section to the base.
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
The condensate drain pan
is shown here with the
inspection plate and gasket
installed. This can be done
before or after the condensate drain pan is bolted to the
boiler.
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.
4. Install each bolt with two flat washers,
one split lock washer and nut (provided). Insert the bolts from the top.
5. Tighten just until the split lock washer
has flattened.
3. When in position, lift the pan straight
up and hold firmly against the bottom of the section assembly.
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Step 24 Install condensate drain
connector
The condensate drain pan
is shown here without the
inspection plate and gasket
installed, to be installed in
Step 25, page 11.
1. The condensate drain connector consists of a plate, O-ring and strainer.
See Step 25, page 11 for
details of condensate drain
pan components.
4. Look for underneath while assembling to ensure the condensate drain
connector is properly seated.
2. Assemble the three parts as shown.
3. Insert the assembly into the bottom
of the condensate drain pan.
5. Secure in place with the screws
provided.
Step 25 Install inspection cover
This could be done before
the condensate drain pan
is installed, as shown in
Step 22, page 10.
LEGEND for drawing at right:
The inspection cover is used
for annual inspection of
the section assembly and
condensate handling components.
32 Inspection cover gasket
1. Assemble inspection cover flange
and gasket.
2. Position over condensate drain pan
inspection opening.
30 Hex nuts
31 Inspection cover
33 Condensate drain pan
34 Condensate strainer
35 Condensate drain connector O-ring
36 Condensate drain connector plate
37 Washers
38 Hex bolts
3. Secure with screws provided.
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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11
Step 27 Install combustion chamber
The combustion chamber
material is fragile, and can be
cracked or gouged with incorrect handling. HANDLE
CAREFULLY! DO NOT
use the chamber if it is damaged.
boiler.
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
boiler.
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.
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Step 30 Burner and manifold
REMOVE THE PILOT
ORIFICE ASSEMBLY
before proceeding. The pilot
orifice assembly (shown in
Step 37, page 15) is factoryinstalled in the manifold.
It must be removed before
the manifold is installed to
prevent damage to the pilot
assembly or pilot tube.
Step 31 Apply silicone RTV to top
surface of section assembly
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.
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.
4. After ensuring the pilot tube is
aligned properly, insert the pilot
orifice assembly as shown.
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.
5. Screw the pilot orifice into the
manifold hole securely. DO NOT overtighten.
3. If the pilot tube is not aligned, use a
screwdriver to reach into the manifold hole and coax the pilot tube into
position.
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 section 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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15
Step 40 Apply jacket front insulation
Leather gloves are recommended when handling sheet
metal components. They will
reduce the possibility of cuts
from sheet metal edges.
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 insulation
boiler.
1. Press jacket rear insulation against the
back of the rear panel.
Step 44 Install jacket rear panel
The jacket rear panel is supplied with the igniter and
conduit box installed.
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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17
Step 45 Install flue adapter
Make sure the flue adapter
condensate nipple is located
at the BOTTOM when installed.
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
The boiler is supplied with
two nipples that include
three control tappings. The
nipples are identical, but they
must be positioned differently.
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 tapping.
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
The boiler is supplied with
two nipples that include
three control tappings. The
nipples are identical, but they
must be positioned differently.
1. Apply pipe dope to one of the other
3-inch nipple and the lower left tapping on the rear of the boiler.
2. Install the return nipple in the tapping.
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.
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Step 48 Install the ignition electrode assembly
Check/adjust the igniter
electrode positioning before
installing. They are not factory preset.
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
The gas line nipple is factoryattached to the mounting
brackets. The nipple must
be removed for connection
to the gas train. This step ensures the nipple is correctly
placed when re-attached to
the bracket.
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1. Use a marker pen to mark the location of the two mounting clamps on
the gas line nipple.
2. Mark the gas line nipple to indicate
which end is the top.
19
Step 51 Mount the control panel
The control panel mounts on
the mounting clip at the top
of the jacket front panel. The
conduit fitting and the sensor
hose must be routed through
jacket panel.
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
Use two wrenches to prevent
damage to gas train components.
20
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 mounting 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
P/N 42-9551
1. Install the gas line grommet provided
into the gas line opening on the bottom of the air box.
21
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 grommetfitteded opening in the bottom of the
air box.
Step 59 Attach the air box/blower
assembly to the manifold blower
flange
Step 60 Tighten gas line nipple
clamps and gas train clamp
1. Use the nuts provided to secure the
assembly to the manifold blower
flange.
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.
22
P/N 42-9551
Step 62 Install gas valve by-pass
line
De-burr the aluminum tubing after cutting to ensure the
ends are not obstructed.
1. Connect an aluminum tube (supplied 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 tapping).
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 ensure 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
boiler.
P/N 42-9551
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 assembly at the top rear of the manifold.
23
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.
24
P/N 42-9551
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
boiler.
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
P/N 42-9551
1. Install a jacket top panel strip on each
side of the jacket top.
25
Step 74 Connect wires to air box
components
See the wiring diagrams,
Figure 1, page 28 and Figure 2, page 30 for detailed
information.
Step 75 Connect wires to air box
components
information.
1. Connect the wires from the air pressure switch and relief valve switch to
the control panel.
2. See callout 3 in schematic wiring
diagram, Figure 1, page 28.
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, Figure 1, page 28.
Step 76 Connect motor wires
information.
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.
26
P/N 42-9551
Step 78 Install the air box cover
The air box cover MUST be
in place during boiler operation.
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.
P/N 42-9551
27
Figure 1
Schematic wiring diagram (numbered bullets show locations of wiring field connections (all wires color coded and numbered)
7
1
2
28
P/N 42-9551
Figure 1
(Continued)
7
3
4
5
6
P/N 42-9551
29
Figure 2
30
Ladder wiring diagram
P/N 42-9551
Figure 2
P/N 42-9551
(Continued)
31
32
P/N 42-9551

Hydrotherm KN

Transcription

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