HydroTherm HeatNet KN-20 Field Assembly Instructions

Brand: HydroTherm

Model: HeatNet KN-20

Type: Field Assembly Instructions

HydroTherm HeatNet KN-20 is a gas-fired direct vent cast iron boiler, which provides an efficient and reliable way to heat your home. It features a durable cast iron construction, a high-efficiency burner, and a compact design that makes it easy to install in a variety of spaces. The KN-20 is also equipped with a number of advanced features, such as a built-in self-diagnostic system and a programmable thermostat, that make it easy to operate and maintain.

is manual is intended only for use by a qualied heating installer/technician. Read and follow this manual, all supplements and re-

lated 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. e 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.

Hydrotherm®

Gas-ﬁred direct vent

Cast iron boilers

Model KN-20 only

-Series

Field assembly

instructions

Also read and follow:

KN Series Gas Boiler

Installation & Operating

Instructions and KN

HeatNet Control Manual

2P/N 42-9551

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

Hazard icons

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

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

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 Automati-

cally Fired Boilers, ANSI/ASME CSD-1.

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.

Before assembling the boiler . . .

Verify boiler rating and gas supply

• Before assembling and installing the boiler, check the ratings to en-

sure 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, uncontami-

nated air for combustion, and that vent (and air) piping can be cor-

rectly installed.

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

supply.

• e boiler must not be exposed to dripping or spraying water or to

rain.

• If replacing an existing boiler, nd 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.

Attention:

Use of an approved dust respirator is strongly

recommended when handling the insulating com-

ponents of the boiler.

Electrical shock hazard — Disconnect all electrical

power sources to the boiler before making any electrical

connections.

Label all wires prior to disconnection when servicing

controls. Wiring errors can cause improper and dangerous

operation! Verify proper operation aer servicing.

Failure to comply with the above could result in severe

personal injury, death or substantial property damage.

e 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 sepa-

rate 120 volt 15 amp circuit for the boiler. A properly rated

shut-o switch should be located at the boiler. e 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.

Line voltage eld 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.

DO NOT open any gas valve, or a empt to re the boiler,

until all boilers have been set up and veried following the

instructions in the KN Series Gas Boiler Installation &

Operating Instructions.

Failure to comply could cause a boiler failure, leading to

possible severe personal injury, death or substantial prop-

erty damage.

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

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)

Use gloves when working with

these products as specied in

these instructions and in the

product instructions.

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

Step 1 Place 4x6 boards on base

Ignore the pale e under the

boiler in the manual images

— it is le 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 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

Use leather gloves when li-

ing or moving boiler sections.

Sections are heavy and can

cause severe personal injury

or death if mishandled.

Li section using two

people, following the

recommendations shown in

Step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.

Tighten bolt rmly, but DO

NOT over-tighten — the

cast iron ange could be bro-

ken if too tight. Tighten only

until the split lock washer has

just a ened.

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

Step 5 Prepare section for baﬄe

Use of an approved dust

respirator is strongly recom-

mended when handling the

insulating components of the

boiler.

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

Do not use baes if they

have been broken, cracked,

folded or frayed. Obtain re-

placements before proceed-

ing 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 recom-

mended for this procedure.

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

Step 8 Push nipple lubricant

Rubber gloves are recom-

mended for this procedure.

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

Avoid scarring or damaging

the push nipple or nipple

port surfaces. e push nip-

ple makes a metal-to-metal

seal with the nipple port. Any

surface defects could cause a

leak.

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

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 li-

ing or moving boiler sections.

Sections are heavy and can

cause severe personal injury

or death if mishandled.

Li section using two

people, following the

recommendations shown in

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

Step 16 Install baﬄe

Do not use baes if they

have been broken, cracked,

folded or frayed. Obtain re-

placements before proceed-

ing 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

e draw rods ARE NOT

used to pull the sections

together, only to keep them

rmly in position.

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

DO NOT exceed 30foot-

pounds 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.

10 P/N 42-9551

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

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

Rubber gloves are recom-

mended for this procedure.

e condensate drain pan

is shown here with the

inspection plate and gasket

installed. is can be done

before or aer the conden-

sate 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.

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.

P/N 42-9551

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

Step 24 Install condensate drain

connector

e condensate drain pan

is shown here without the

inspection plate and gasket

installed, to be installed in

Step25,page11.

See Step25,page11 for

details of condensate drain

pan components.

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

is could be done before

the condensate drain pan

is installed, as shown in

Step22,page10.

e inspection cover is used

for annual inspection of

the section assembly and

condensate handling compo-

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

Step 27 Install combustion cham-

ber

e combustion chamber

material is fragile, and can be

cracked or gouged with in-

correct handling. HANDLE

CAREFULLY! DO NOT

use the chamber if it is dam-

aged.

Use of an approved dust

respirator is strongly recom-

mended when handling the

insulating components of the

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

Use of an approved dust

respirator is strongly recom-

mended when handling the

insulating components of the

boiler.

1. Carefully place the burner gasket

on the surface of the combustion

chamber.

Step 29 Apply Resbond adhesive

to the burner gasket

Rubber gloves are recom-

mended for this procedure.

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

Step 30 Burner and manifold

REMOVE THE PILOT

ORIFICE ASSEMBLY

before proceeding. e pilot

orice assembly (shown in

Step37,page15) is factory-

installed in the manifold.

It must be removed before

the manifold is installed to

prevent damage to the pilot

assembly or pilot tube.

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

Rubber gloves are recom-

mended for this procedure.

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.

14 P/N 42-9551

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

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

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.

16 P/N 42-9551

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

Step 40 Apply jacket front insula-

tion

Leather gloves are recom-

mended when handling sheet

metal components. ey 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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KN Series Gas-ﬁred direct vent cast iron boilers – Field assembly instructions

Step 43 Apply jacket rear insula-

tion

Use of an approved dust

respirator is strongly recom-

mended when handling the

insulating components of the

boiler.

1. Press jacket rear insulation against the

back of the rear panel.

Step 44 Install jacket rear panel

e jacket rear panel is sup-

plied with the igniter and

conduit box installed.

Leather gloves are recom-

mended when handling sheet

metal components. ey will

reduce the possibility of cuts

from sheet metal edges.

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.

18 P/N 42-9551

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

Step 45 Install ﬂue adapter

Make sure the ue adapter

condensate nipple is located

at the BOOM when in-

stalled.

Rubber gloves are recom-

mended for this procedure.

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

e boiler is supplied with

two nipples that include

three control tappings. e

nipples are identical, but they

must be positioned dier-

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

e boiler is supplied with

two nipples that include

three control tappings. e

nipples are identical, but they

must be positioned dier-

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.

P/N 42-9551

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

Step 48 Install the ignition elec-

trode assembly

Check/adjust the igniter

electrode positioning before

installing. ey are not fac-

tory 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

e gas line nipple is factory-

a ached to the mounting

brackets. e nipple must

be removed for connection

to the gas train. is step en-

sures the nipple is correctly

placed when re-a ached to

the bracket.

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

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

Step 51 Mount the control panel

e control panel mounts on

the mounting clip at the top

of the jacket front panel. e

conduit  ing 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 compo-

nents.

1. Use two pipe wrenches to tighten the

gas line nipple connection.

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HydroTherm HeatNet KN-20 Field Assembly Instructions

Brand: HydroTherm

Model: HeatNet KN-20

Type: Field Assembly Instructions

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HydroTherm HeatNet KN-20 Field Assembly Instructions

HydroTherm HeatNet KN-20 Field Assembly Instructions

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