HydroTherm HeatNet KN-16 User manual

is manual is intended only for use by a qualied heating installer/technician. Read and follow this manual, all supplements and related
instructional information provided with the boiler. Install, start and service the boiler only in the sequence and methods given in these
instructions. Failure to do so can result in severe personal injury, death or substantial property damage.
Do not use the boiler during construction. Construction dust and particulate, particularly drywall dust, will cause contamination of
the burner, resulting in possible severe personal injury, death or substantial property damage. 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.
Ax these instructions near to the boiler/water heater. Instruct the building owner to retain the instructions for future use by a qualied
service technician, and to follow all guidelines in the User’s Information Manual.
10/12 Copyright 2010 Hydrotherm
Gas-Fired Cast Iron Boilers
Models KN
-1 6, -26, and -30
KN-FAI2-0313
42-9552
Also read and follow:
KN Series Gas Boiler
Installation and Operating
Instructions
and
KN HeatNet Control Manual
Field Assembly
Instructions

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INFORMATION
This manual is intended only for the field assembly of
a KN-16, -26 or -30 boiler. Follow the assembly
instructions in sequence. Also follow all requirements
of the KN Boiler manual and the KN HeatNet manual.
BLOCK ASSEMBLY SEQUENCE
These instructions show block assembly
beginning with the front section and finishing
with the back section.
Ifjobconditionsmakethisimpractical,theblock
canbe builtbeginning with thebacksectionand
finishing with the front.
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
thatareimportant,butarenotrelatedtohazards.
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 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.
READ BEFORE PROCEEDING
Customer Service AndTechnical 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
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,ANSIZ223.1/NFPA 54-latestrevision.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.
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 ASSEMBLINGTHE BOILER . . .
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.
• 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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ATTENTION:
Use of an approved dust respirator is
strongly recommended when handling the
insulating components 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 after servicing.
Failure to comply with the above could result in
severe personal injury, death or substantial
property damage.
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.
Linevoltagefield wiring ofanycontrolsor other
devices must use copper conductors with a
minimum size of #14 awg.Use appropriate
wiring materialsforunits installed outdoors.
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.
Failure to comply could cause a boiler failure,
leading to possible severe personal injury,
death or substantial property damage.
COMPONENTS AND
SPECIALTOOLS REQUIRED
Recommended Assembly Crew
The assembly crew should be a minimum of
3experienced technicians.
Equipment/Materials Required For Assembly
1. One quart 30-wt motor oil
2. Flexible leather work gloves
3. Dead-blow hammer with plastic face (DO NOT use a
sledge hammer)
4. Four 2" x 4" x 12" boards (used for cushioning when
seating push nipples)
5. Two 18 inch pipe wrenches (plus 2 inch x 2 feet
cheater pipe)
6. Crescent wrenches, 18 inch or larger, may be used for
tightening the draw rod nuts (NOT tie rods). (See
Step 16, page 10 for draw rod instructions.)
7. Torque wrench (at least 30 foot-pound capacity)
8. Deep socket, 11/16 inch for use with torque wrench
9. Standard hand tools.
10. Wire, wire nuts, electrical hand tools (crimper, stripper,
etc.).
Boiler Components And Shipping Information
Check the contents of the skids against the
Bill of Materials/Checklist shipped with the
boiler. Use the Checklist to locate specific items
throughout the assembly process. Content
your Hydrotherm supplier if you discover any
components damaged or missing.
The boiler is shipped in two skids and one crate. See the
contents of the crates and skids in Figure 2, page 23.
Sealants, lubricants and adhesives supplied with
boiler (see Figure 2, page 23 for location)
Use gloves when working with these products
as specified in these instructions and in the
product instructions.
1. Silicone RTV-6500 HiTemp: 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: 8-oz jar (for mixing with 30-wt
motor oil, used as lubricant for push nipples)
4. Fast-Tack 87: (1) 13-oz spray can (for securing flue
baffles to sections)

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Step 1 Place runner beams on base (see BLOCK ASSEMBLY SEQUENCE NO-
TICE on page2 — assembly can be from back to front if necessary)
Make sure the boiler base is in the correct position before
starting. The legs extend longer on the FRONT end of the base
than on the rear end (approximately 9-1/2 inch at front and 6-3/4
inch at rear — use a tape measure if necessary to compare).
FRONT END
FRONT END
(legs extend longer at
(legs extend longer at
front than at rear)
front than at rear)
REAR END
REAR END
LOCATE BOILER TO
PROVIDE MINIMUM
CLEARANCES FOR
ASSEMBLY AND AS
REQUIRED BY KN BOILER
MANUAL:
e boiler must be installed
in accordance with the KN
Instruction Manual — the
boiler location must maintain
all required clearances for
service and spacing from
combustible surfaces.
In addition, provide:
AT LEAST 60 INCHES
clearance at the front of
the boiler to allow room for
block and condensate pan
assembly.
1. Remove base from skid.
2. The base is symmetrical, so either end
can be placed as the front end.
3. Place a beam (supplied) against each
side as a runner as shown at right.
4. The planed surface of the beam must
be on top.
5. If beam has any curvature, place the
beam with the curvature toward the
OUTSIDE of the frame.
6. Space runner beams with about even
lengths extending o of each end of
the base.
7. The runner beams will be used to
support the boiler block during
assembly, then removed afterward.
Step 2 Oil top surface of runner beams
DO NOT allow oil to drip
on the oor.
Make sure the oor is free
of any slick spots and that
there is no debris or any
obstruction in the work area
or walk path to boiler parts.
1. Use a paint brush to spread 30-wt
motor oil on the runner boards. This
allows sections to move easily during
draw-up.
Step 3 When lifting the sections
Useleathergloveswhen
liingor movingboiler
sections.Sections areheavy
andcan cause severepersonal
injuryor deathif mishandled.
Lift section using two
people.Then place in
position on the runner
beams. Make sure
the section is always
supported to prevent
tipping or falling.
1. Lift section with each person lifting at
the bottom of the section.
2. Move onto the runners and slide into
position.
3. Handlers should lift with their legs to
avoid back strain.

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Step 4 Place the FRONT section
Use leather gloves when
liing or moving boiler
sections. Sections are heavy
and can cause severe personal
injury or death if mishandled.
Have someone support the
section during this step and
the next. e sections are
top-heavy and could easily
fall if not supported.
Handle all sections with
care to prevent any
damage to machined
surfaces.
1. Identify the FRONT section — its
lower nipple port is on the LEFT side
when looking at the inside of the
section, as in this photo.
2. Slide the front section to the end of
the base.
3. Lift into position and have someone
hold securely.
Step 5 Bolt front section to base
1. Use a 3/8 x 6 inch bolt, wedge, at
washer, split lock washer and nut on
each side as shown.
2. Point the wedge narrow edge toward
the section.
Wedge —
Point thin edge
toward the section.
Tighten bolt rmly, but DO
NOT over-tighten — the
cast iron ange could be
broken if too tight. Tighten
only until the split lock
washer has just aened.
e bolt must be secure to
prevent movement of the
front section during the next
steps of assembly.
Step 6 Apply adhesive for ceramic ber ue bae
DO NOT SPRAY adhesive
on the nipple port
machined surfaces. is
would prevent proper sealing
with the silicone sealant
applied later.
1. Obtain the spray adhesive supplied in
the hardware box.
2. Spray ONLY the heat pin area of the
casting with the spray adhesive.
3. The adhesive is required to secure the
ue bae (next step) in the ueway.
.
3
.
The
adhesive
is
required
to
secure
th
e
ue bae (next step) in the uewa
y
.

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Step 7 Place ceramic ber bae in ueway
Use of an approved dust
respirator is strongly
recommended when
handling the insulating
components of the boiler.
Do not use ue baes if
they have been broken,
cracked, folded or frayed.
Obtain replacements before
proceeding with the boiler
assembly.
1. The cut-o corner of the bae must
go to the lower left corner. Align the
bae in this position to determine
which side to spray with adhesive.
2. Apply spray adhesive to the back side
of a ceramic ber bae.
3. Place the bae in the heat pin area of
the front section as shown.
4. Press bae into place.
5. Position the bae so that it does
NOT overlap onto the edge
surfaces of the section. This would
prevent the section from drawing up
correctly.
Step 8 Mix push nipple lubricant
Work gloves are
recommended 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. Mix about 1part of oil to
20parts of the pipe dope.
2. The consistency should be similar to
thick paint and should ow easily.
3. You will need enough mixture to
lubricate all nipple ports and all push
nipples — about 1/2 pint.
Step 9 Lubricate nipple ports
DO NOT get oil on the
FACES of the nipple ports
— apply lightly and ONLY
on the inside machined
surfaces.
If oil gets on a port face, wipe
o with a clean rag dipped
in a solvent such as mineral
spirits. Oil will prevent the
silicone sealant from sealing
properly.
1. Use a clean rag to wipe o all
machined surfaces on both sides
of the section before proceeding.
2. Also wipe clean the inside machined
surfaces of both nipple ports on fornt
and back of section.
3. After cleaning the ports, brush pipe
dope/oil mixture on the INNER
machined surfaces of the nipple ports
ONLY.

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Step 10 Apply RTV to machined surfaces
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 ue
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 ueways.
Step 11 Lubricate push nipples with oil/pipe dope mixture (see Step 8)
Inspect push nipples carefully
before using. DO NOT use
a nipple if it is gouged or
scarred.
DO NOT apply excessive
lubricant to the nipple
ports. Lubricant can drip
onto the machined sealing
surface, preventing the
RTV sealant used later from
sticking.
1. Obtain two push nipples.
2. Inspect carefully and wipe o the
nipples with a clean cloth.
3. Brush the outside surface of each
push nipple VERY LIGHTLY with the
push nipple lubricant.
4. Wipe o any excess lubricant.
Step 12 Insert push nipples
Avoid scarring or damaging
the push nipple or nipple
port surfaces. e push
nipple 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 rmly 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.
Step 13 Seat the push nipples
Use only a dead blow hammer
to seat the push nipples. DO
NOT use a sledge hammer.
1. Place a 2x4 board across the nipple and
strike rmly with a dead-blow hammer.
2. Make sure to strike in the center of the
nipple to prevent rotating it.
3. Do this with several strokes, just so the
push nipple is rmly started.
4. Look into the nipple ports from the end
of the boiler. When properly seated at
this point, the push nipple edge should
be slightly inside the nipple port. It
should also be parallel with the inside
surface.

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Step 14 File lower edges of next section
Work gloves are
recommended for this
procedure.
1. Use a at le to ease o the front
lower edge on both sides of the next
section.
2. This step will prevent the sharp edges
from gouging the runner beams as
the section is drawn up.
Step 15 Install next section and prepare draw rods
1. Carefully slide the rst intermediate
section up to the front.
2. Before pulling the intermediate section
up fully, clean the nipple ports and
brush lubricant on the inside machined
surfaces of the nipple ports as in Step9.
3. Align the intermediate section to the
front section and slowly move into
position so both push nipples just
enter the intermediate section.
4. To initially seat the push nipple into the
next section, rap with a dead blow
hammer and 2x4 at each nipple port.
5. Repeat, alternating from right nipple
port to left to avoid cocking the push
nipples.
6. Wipe a small amount of motor oil on
the 7/8 inch all-thread rods supplied
with the boiler to make pull-up easier.
7. Place a 3/4 inch nut and washer plus
one of the bearing plates one each of
the two draw rods. The back sides (large
surface) of the bearing plates must face
toward the sections (away from the
nuts). The ribbed side of the bearing
plate (shown in the photo below) must
face the nut.
7/8-inch nuts and washers
Bearing
Bearing
plates
plates
Place bearing plate with flat side
Place bearing plate with flat side
away from the nut.
away from the nut.
When block assembly is
completed with the rear section,
use a small bearing plate on the
rear section as well, with the
ribs pointed inward.
8. Thread the nut far enough that about
24inches of draw rod extends beyond
the bearing plate.
9. Carefully insert the draw rods through
the front nipple ports. (Most of the draw
rod length will extend to the front.)
10. Slide one of the bearing plates over the
back end of each draw rod until ush
with the intermediate section port. The
bearing plate ribs should be toward the
nut, with at side against the section.
Hold the draw rods up while
positioning to prevent the draw
rod threads from gouging the
nipple port machine surfaces.
11. Thread a washer and nut onto the
back end of each draw rod and snug
against the bearing plate. Make sure
the bearing plates are centered on the
nipple ports.
12. As additional sections are added, lay a
rag in the bottoms of the nipple ports
to prevent damaging the machined
surfaces as the draw rods are passed
through.

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Step 16 Draw sections together using draw rods and dead blow hammer
1. Use wrenches to pull the sections
together.
2. Alternate from one side to the other
during pull-up to avoid cocking the
nipple ports.
3. Use the dead blow hammer
to assist in the pull up.
4. The dead blow hammer will cause a
thud when struck against the section
until the sections are tight together.
When the draw up is complete, the
dead blow hammer should cause a
ringing sound from the block.
5. When the sections are properly pulled
up, they will be nearly metal-to-metal.
6. Look inside the nipple ports from the
end and inspect the push nipples. They
should be parallel with the section face
and about 1/8inch from the inside
surface of the section.
Push nipple edge
Push nipple edge
about 1/8 inch from in-
side surface of section
f
se
ct
io
f section
Step 17 Install remaining intermediate sections and then the rear section (see previous pages for details)
Step 6
Apply adhesive for
ceramic ber ue
bae
Step 11
Lubricate push
nipples with oil/
pipe dope mixture
(see Step 8)
Step 14
File lower edges of
next section
Step 7
Place ceramic ber
bae in ueway
Step 12
Insert push nipples
Step 15
Install next section
and prepare draw
rods
Step 9
Lubricate nipple
ports
Step 13
Seat the push
nipples
Step 16
Draw sections
together using
draw rods and
dead blow
hammer
Step 10
Apply RTV to
machined surfaces
Read all instructions thoroughly and follow all WARNINGS and
NOTICES included in the steps referenced here.
Handle all sections with care to prevent any damage to
machined surfaces.
BLOCK ASSEMBLY SEQUENCE — See NOTICE on page2.
Before attempting to install
the REAR SECTION, bend
down the tabs on the rear
legs as at right:
1. Bend down the end tabs on
the two rear legs at right. This is
required so that the rear section
can slid into position along the
runner beams. Use a hammer to
bend back into position after the
block assembly is completed.

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Step 18 Remove the runner beams and bolt block to base
The block assembly is
extremely heavy. Use care
as the beams are removed to
ensure the block does not slide
during the process.
1. When the section assembly is
completed, leave the draw rods
in place so section joints are secure
while the block is manipulated.
2. Remove the two bolts and hardware
from the bottom of the front section.
Remove the mounting
Remove the mounting
bolts from the bottom
bolts from the bottom
of the front section.
of the front section.
3. Use pry bars at each leg (front and back)
on one side of the base. Tilt the block
only enough to allow sliding the runner
beam.
4. Pull the runner beam out.
5. Ease the block down so it rests on the
front and rear legs.
6. Repeat the process with pry bars on the
other side of the block and remove the
remaining runner beam.
7. Check alignment of the section leg slots
with the hole in the legs — pry section
into position as needed.
8. Install the 3/8 x 4-1/2 inch bolts, nuts,
washers and wedges on all four legs (as
in Step5).
Step 19 Insert the tie rods, then tighten tie rod nuts using a torque wrench
The tie rods ARE NOT
used to pull the sections
together — ONLY to keep
them rmly in position.
1. After the block has been bolted to the
four legs, remove the draw rods, nuts
washers and bearing plates.
2. When the section assembly is complet-
ed, slide a 1/2 inch tie rod through each
of the four tie rod holes.
3. Apply a washer and nut on each end
and pull up nger tight.
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 rst.
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 nish
the tightening to 30foot-pounds for
each nut.

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Step 20 Remove excess silicone sealant along top of block and in chamber area
1. Remove excess silicone sealant along
the top the block until it is ush with
the machined surface.
2. Remove any excess silicone that may
have extruded into the interior of the
section assembly.
3. This area must not have any blockage
where the combustion chamber will be
inserted.
Step 21 Prepare condensate pan
Rubber gloves are
recommended 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
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 ange around the
complete perimeter.
2. At each of the four corners, apply a
bead on the ange where the sheet
metal edges meet.
Step 22 Install condensate drain pan
The condensate drain pan must be sealed completely around all edges to prevent ue gas leakage.
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 rmly against the bottom of
the section assembly.
4. Install each bolt with two at washers,
one split lock washer and nut (provided).
Insert the bolts from the top.
5. Tighten just until the split lock washer
has attened.
Step 23 Install inspection port plugs
1. Apply pipe dope (supplied with boiler)
to plugs (supplied) and install in each
of the inspection ports, located at the
lower right side of each section.
2. Also install plug in all top tappings.

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Step 24 Apply jacket rear insulation and jacket rear panel (temporarily) and install supply and return manifolds
Use of an approved dust respirator is strongly recommended when handling the insulating components of the boiler.
1. Insert and drive in the jacket front studs
(nine locations).
2. Press jacket front insulation over the
four boss tappings (foil side out).
3. Position the jacket rear panel over the
tapped boss or four boss tappings and
use a single nut to temporarily fasten
the panel in place. Finger tighten the
nut only.
4. Use a knife to cut the insulation at the
supply and return openings.
5. Use pipe dope and pipe tape on
threads of supply and return manifolds
and install in 4 inch rear tappings.
Mount return manifold (gure 7) with
drain valve in bottom position.
6. OUTLET MANIFOLD:
Flow switch
Flow switch
Outlet temp
Plugged
p
p
d
7. RETURN MANIFOLD:
Plugged
Drain
Drain
Return temp
Step 25 Hydrostatically test the boiler
DO NOT exceed the test
pressure specied here by
more than 10PSI.
DO NOT leave boiler
unattended. Excess
pressure could develop,
resulting in severe damage.
Repair all leaks at once. If
block leaks should occur,
repair if possible. Contact your
Hydrotherm representative for
instructions if necessary.
1. Apply blanking anges and gaskets to
the 4 inch anged supply and return
connections at the boiler rear.
2. Apply pipe dope and pipe tape to the
two 3 inch recessed plugs and install
in the front section (top left and lower
right). Driver is supplied with boiler.
3. Plug any unused openings in the boiler.
4. Pipe a shut-o valve to one of the top
tappings for bleeding air during ll and
drainage.
5. Remove the boiler drain valve from the
return manifold.
6. Pipe a shut-o valve, water supply
and drain line to the boiler drain valve
tapping.
7. Fill the boiler (bleeding air from top
valve) completely with clean water.
8. Use a hand pump or other means to
raise the water pressure in the boiler to
150PSIG.
9. Close valves and observe the pressure
gauge for at least 10minutes to ensure
the boiler is pressure tight.
10. If pressure drops, perform a thorough
inspection to locate the leak.
11. Repair any leaks found before
proceeding.
12. Once hydrostatic test is successful, drain
the boiler completely.
13. Remove the temporary piping.
14. Re-install the boiler drain valve.
15. Install the boiler relief valve in the rst
tapping on the top rear of the boiler.

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Instruction
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Step 26 Install burner inspection ports (front and rear)
1. Each 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. DO NOT overtighten.
Step 27 Install the combustion chamber
e 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.
Use of an approved dust
respirator is strongly
recommended when handling
the insulating components of
the boiler.
1. Remove the combustion chamber
sections (four pieces) from the shipping
tubes and remove protective packaging.
2. Carefully place the four combustion
chamber side pieces in the top as
shown.
3. The combustion chamber should sit
evenly in the opening, with its FLAT
surface facing up and even with the
surface of the sections.
4. Use the loose ceramic ber wadding
supplied with the boiler to pack the
corners of the chamber. This will hold
the pieces rmly in position and ensure
a tight seal at the joints.
Step 28 Install the burner gasket and apply silicone sealant to top machined surface of boiler
Make sure the silicone sealant is continuous. Failing to provide a complete seal could result in the leakage of
combustion gases.
Use of an approved dust
respirator is strongly
recommended when handling
the insulating components of
the boiler.
1. Carefully place the burner gasket on the
surface of the combustion chamber.
2. Apply a generous bead of silicone
sealant completely around the outside
the chamber on the machined surface.

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Step 29 Install the burner
Make sure the silicone sealant is continuous. Failing to provide a complete seal could result in the leakage of
combustion gases.
Use of an approved dust
respirator is strongly
recommended when handling
the insulating components of
the boiler.
1. Carefully place the burner on top of the
burner gasket.
2. Apply a generous bead of silicone
sealant completely around the outer
edge of the burner.
Step 30 Install the burner ange
Make sure the silicone sealant is continuous. Failing to provide a complete seal could result in the leakage of
combustion gases.
Use of an approved dust
respirator is strongly
recommended when handling
the insulating components of
the boiler.
1. Carefully align the burner ange on top
of the burner.
2. Apply a generous bead of silicone
sealant completely around the ange,
about 1inch inside the bolt notches.
Step 31 Install the manifold
Make sure the silicone sealant is continuous. Failing to provide a complete seal could result in the leakage of
combustion gases.
Use of an approved dust
respirator is strongly
recommended when handling
the insulating components of
the boiler.
1. Carefully align the manifold (with the
blower ange toward the front of the
boiler) and lower onto the boiler.
2. Hold the manifold securely in place
while installing the retainer bolts.
3. Install bolts in all slots around the
manifold ange.
4. Work from the center out on the sides
and ends to prevent buckling.
5. If necessary, use padded clamps to pull
the manifold edge down enough to
place the bolts and washers.
6. The jacket rear panel can be slid out of
the way during this process if necessary
for access to bolts.

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Instruction
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Step 32 Install the rear jacket and ue collar
Make sure the silicone sealant is continuous. Failing to provide a complete seal could result in the leakage of
combustion gases.
1. Press the rear jacket panel over the
studs and apply nuts (seven places)
securely.
2. Apply a generous bead of silicone
sealant completely around the ue
collar boss on the rear section. Keep
the bead inside the bolt holes.
3. Position the ue collar on the boss and
secure with the bolts provided.
Step 33 Install jacket top left panel and top-mounted controls and trim
1. See the following for placement of
components.
2. Plug any tappings that will not be used
before placing the jacket top panel
and then installing the top-mounted
components.
3. Place the jacket top panel over the top
openings (after plugging opens that
won’t be used).
4. Top rear tappings.
Rear 1
Rear 1
Rear 2
Rear 2
Rear 3
Rear 3
Rear 4
Rear 4
5. Rear 1 is for relief valve.
Rear 2 is for the MANUAL rest high limit.
Rear 3 is for the air vent.
Rear 4 is for the low water cuto.
6. Top front tappings.
Front 1
Front 1
Front 2
Front 2
7. Front 1 is for a bushing and the
pressure/temperature gauge.
Front 2 is for the automatic reset limit.
Step 34 Wire connections to rear terminal box
1. Remove the cover on the rear terminal
box.
2. Route ex conduits to the bushings
mounted on the rear terminal box.
Wires are color coded. Connect wires
to match the wires connected to the
bottom of the terminal block.
3. The harness from the rear terminal block
will be attached to the control panel (on
front of boiler) in Step38.

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Instruction
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Step 35 Install condensate drain trap assembly
The condensate drain pan trap be sealed to the drain pan with the gasket provided to prevent ue gas leakage.
1. Condensate drain trap components.
2. The trap assembly bolts to the bottom
of the drain pan (below).
3. Place the gasket on the trap ange and
place against the drain connection.
4. Insert the two bolts and washers
through the ange and tighten.
5. Apply the U-bolt as shown. Secure to
the base front crossover using the nuts
provided.
Step 36 Install 5
Use of an approved
dust respirator is strongly
recommended when handling
the insulating components of
the boiler.
1. Insert and drive the jacket front studs
into the stud bosses (nine locations).
2. Cut cross slots in the insulation at each
stud location and press the insulation
onto the studs. Slide a steel spacer over
each stud.
3. Place the jacket front panel over the
studs and secure with nuts and washers
provided.
4. They come welded to the sheet stainless
steel (two) and are stand-os not osets
and nuts/washers in locations shown at
right. Note that some locations are for
use in attaching other components.
5. Location 1 (2 studs) — used later for
blower housing bracket.
6. Location 2 (4 studs) — for mounting
control assembly back plane.
7. Location 3 (3 studs) — apply nuts and
washers to secure the jacket panel.
8. Location 4 (4 studs) — used later for
attaching gas train bracket.
1
1
2 2
2 2
3 3 3
44
44

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Step 37 Install the blower housing
1. Place the blower housing bracket over
the top two studs.
2. Rest the blower housing on the bracket
and secure the four bolts between the
blower housing ange and the
manifold.
3. Install the bolts and nuts between the
bracket and the blower housing.
4. Adjust the blower housing until level
and tighten the mounting bolts on the
bracket at boiler front and at housing.
Step 38 Install the control panel and connect wiring
1. Slide the control panel onto the studs
and secure with nuts provided.
2. Connect the loose wires (identied with
destination tags).
3. Make sure all of the following connections are made. Some of these connections will
be made in later steps as additional components are added. See the wiring diagrams
supplied with the boiler for details. The following is a list of connections to be made.
Wires are tagged with destinations.
4. When boiler assembly is complete, follow the boiler manual and the wiring diagrams to
complete eld control wiring and power connections.
TAGGED WIRING CONNECTIONS
Rear
terminal box
Low water cut-o
MR limit
Flow switch
Outlet temperature sensor
Return temperature sensor
Control
enclosure
(front)
Wires from rear terminal block (LWCO, ow switch, MR limit, outlet
temperature sensor, and return temperature sensor)
Blower motor harnesses
Gas pressure switches
Main gas valve
Pilot gas valve
Filter box rupture disk switch
Ignitor cable to spark generator
Ignitor ground lead to ground bar
UV scanner wires
Display panel wiring

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Instruction
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Step 39 Access the blower housing interior, adjust magnetic damper closure and connect wiring
1. Remove the covers on the blower
housing.
2. Check the gap between the magnet
and the strike plate when the damper
is closed. Adjust until gap is between
1/8 inch and 1/4 inch.
Set gap between
magnet and strike
plate to about ¼”
e
e
3. Connect wires from blower housing
components to control panel.
Step 40 Adjust the ignition electrode/UV scanner assembly and install
1. Check/adjust insertion length (from
ignition electrode ange to inside end
of ceramics). This dimension must be
1-1/2 inches.
2. Check/adjust the gap between the
electrode tips. This dimension must be
1/8 inch
3. Apply the gasket and bolt in place
using the hardware provided. DO NOT
overtighten. Connect wires.
Step 41 Install the jacket left side insulation and panel
Use of an approved dust respirator is strongly recommended when handling the insulating components of the boiler.
1. Insert left side insulation under the top
left panel.
2. Tuck in the insulation at the bottom to
hold in place (note that wire harness
from rear is in FRONT of insulation)
3. Lift the top left panel out of the way and
install the jacket left side panel, making
sure all tabs t into the mating grooves
in front and rear jacket panels.

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Instruction
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Step 42 Install the jacket right side insulation and panel; install control enclosure side panels
Use of an approved dust respirator is strongly recommended when handling the insulating components of the boiler.
1. Apply spray adhesive to the back side of
the jacket right side insulation. Also
apply to the right side of the boiler block.
2. Press the insulation against the right
side of the boiler. Hold in place long
enough for the adhesive to set. If the
insulation slips, have someone hold it in
place until the jacket panel is applied.
3. Install the jacket right side panel,
making sure all tabs t into the mating
grooves in front and rear jacket panels.
4. Install the control enclosure side panels
using screws provided.
Step 40 Adjust the ignition electrode/UV scanner assembly and install
1. Check/adjust insertion length (from
ignition electrode ange to inside end
of ceramics). This dimension must be
1-1/2 inches.
2. Check/adjust the gap between the
electrode tips. This dimension must be
1/8 inch
3. Apply the gasket and bolt in place
using the hardware provided. DO NOT
overtighten. Connect wires.
Step 44 Install plastic sense line tubing and aluminum tubing
1. Install plastic hoses as shown in
Figure1. Lines connect between hose
barb connections in blower housing
and components in control panel.
2. Install aluminum tubing connections
(four). Tubes are labeled with destina-
tions. See Figure1.

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Instruction
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20
Step 45 Replace access panels on blower housing
1. Re-install all access panels on the
blower housing.
Step 46 Complete wiring
1. Obtain the HeatNet display panel
assembly.
2. Complete all wiring connections from
the control panel to the display panel
components.
3. Mount the display panel and the control
enclosure front panel.
4. Complete all wiring connections and
secure conduit ends.
5. Install the control enclosure cover panel,
electrical cover panel and gas train
cover panel.