AHRI APEX Installation, Operating And Service Instructions Download Page 1

Page: 1 / 124

104707-03 - 4/14

Price - $5.00

WARNING:

Improper installation, adjustment, alteration, service or maintenance can cause property damage,

injury, or loss of life. For assistance or additional information, consult a qualifi ed installer, service agency or the

gas supplier. This boiler requires a special venting system. Read these instructions carefully before installing.

INSTALLATION, OPERATING AND

SERVICE INSTRUCTIONS FOR

APEX

™

CONDENSING HIGH EFFICIENCY

DIRECT VENT

GAS - FIRED HOT WATER BOILER

9700609

Summary of Contents for APEX

Page 1: ... of life For assistance or additional information consult a qualified installer service agency or the gas supplier This boiler requires a special venting system Read these instructions carefully before installing INSTALLATION OPERATING AND SERVICE INSTRUCTIONS FOR APEX CONDENSING HIGH EFFICIENCY DIRECT VENT GAS FIRED HOT WATER BOILER 9700609 ...

Page 2: ...cense reg state ma us pubLic pl_products pb_pre_form asp for the latest Approval Code or ask your local Sales Representative The Commonwealth of Massachusetts requires this product to be installed by a Licensed Plumber or Gas Fitter DANGER Indicates an imminently hazardous situation which if not avoided will result in death serious injury or substantial property damage CAUTION Indicates a potentia...

Page 3: ...ll be permanently mounted to the exterior of the building at a minimum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS 4 A final inspection by the state or local gas i...

Page 4: ...ing 51 VIII Electrical 55 IX System Start Up 67 X Operation 75 A Overview 75 B Supply Water Temperature Regulation 76 C Boiler Protection Features 77 D Multiple Boiler Control Sequencer 78 E Boiler Sequence of Operation 79 1 Normal Operation 79 2 Using the Display 80 F Viewing Boiler Status 81 1 Status Screens 81 2 DetailScreens 82 3 Multiple Boiler Sequencer Screens 83 G Changing Adjustable Param...

Page 5: ...6 157 22 1 8 562 N A N A 28 3 8 724 C Inch mm 13 1 16 332 29 737 24 610 24 610 34 1 4 876 D Inch mm 23 3 4 602 39 11 16 1008 38 7 8 987 38 7 8 987 48 1 16 1226 E Inch mm 15 13 16 402 29 3 8 752 31 5 8 803 31 5 8 803 33 13 16 864 Gas Inlet F FPT 3 4 3 4 1 1 1 Return G 1 1 2 FPT 2 MPT 2 MPT 2 MPT Supply H 1 1 2 FPT 2 MPT 2 MPT 2 MPT Condensate Drain J Factory Provided Socket End Compression Pipe Joi...

Page 6: ...6 I Product Description Specifications and Dimensional Data continued Figure 1A Apex Model APX425 ...

Page 7: ...7 Figure 1B Apex Model APX525 I Product Description Specifications and Dimensional Data continued ...

Page 8: ...8 I Product Description Specifications and Dimensional Data continued Figure 1C Apex Models APX625 and APX725 ...

Page 9: ...9 I Product Description Specifications and Dimensional Data continued Figure 1D Apex Model APX825 ...

Page 10: ...sea level and elevations up to 2000 ft For elevations above 2000 ft the boiler will naturally derate by 2 5 for each 1000 ft above sea level 1 Net AHRI Water Ratings based on allowance of 1 15 Consult manufacturer before selecting boiler for installations having unusual piping and pickup requirements such as intermittent system operation extensive piping systems etc II Unpacking Boiler NOTICE Do n...

Page 11: ...bustible material clearance providing III Pre Installation and Boiler Mounting 1 Access to boiler front is provided through a door or removable front access panel 2 Access is provided to the condensate trap located underneath the heat exchanger 3 Access is provided to thermal link located at boiler rear D Protect gas ignition system components from water dripping spraying rain etc during boiler op...

Page 12: ...ondensate trap located on the left side of boiler 3 Access is provided to thermal link located at the boiler rear 4 Boiler Installation a For basement installation provide a solid level base such as concrete where floor is not level or where water may be encountered on the floor around boiler Floor must be able to support weight of boiler water and all additional system components b Boiler must be...

Page 13: ... left corner and align bracket two upper holes with corresponding side panel lower dimples The remaining lower bracket hole must align with a matching bottom boiler left side panel top positioning dimple Once bracket holes and side panel dimple alignment is verified attach the bracket to top and bottom boiler left side panels with the mounting screws e Repeat above procedure to install second stac...

Page 14: ... combination c Water Piping and Trim Follow instructions in Section VI Water Piping and Trim of the manual for system piping and boiler secondary piping selection sizing based on combined heating capacity and or gross output of the selected stackable boiler combination Follow instructions of Section VI Water Piping and Trim for each individual boiler trim installation d Electrical Follow instructi...

Page 15: ...alculations Use vent combustion air equivalent length worksheet provided in Table 6B b Maintain minimum clearance to combustible materials See Figure 2 for details c Enclose vent passing through occupied or unoccupied spaces above boiler with material having a fire resistance rating at least equal to the rating of adjoining floor or ceiling Note For one or two family dwellings fire resistance rati...

Page 16: ... 6B 9 12 14 10A 10B Optional Vertical Vertical through roof or chimney chase The system includes separate Flexible Polypropylene vent liner and Rigid Polypropylene vent pipe combination for venting and Rigid Polypropylene or PVC air intake pipe terminating through roof with individual penetrations for the vent and air intake and separate terminals 7 through 9 14 15 10A 10B Available Optional Two P...

Page 17: ...iser que les sections horizontales doivent être supportées pour Table 6A Vent System and Combustion Air System Components Equivalent Length vs Component Nominal Diameter Vent or Combustion Air System Component Description Equivalent Length for Vent or Combustion Air System Component vs Component Nominal Diameter Component Nominal Diameter 4 in 100 mm or 110 mm 6 in 150 mm or 160 mm 90 Elbow Short ...

Page 18: ... mm or 110 mm 13 ft 4 0 m 6 in 150 mm or 160 mm 7 5 ft 2 3 m 6 in 150 mm or 160 mm 22 ft 6 7 m Straight Pipe Installer Supplied 45 Elbow s Installer Supplied Nominal Diameter Quantity Length ft or m Equivalent Length ft ft or m m Subtotal Equivalent Length C Nominal Diameter Quantity Length ft or m Equivalent Length ft ft or m m Subtotal Equivalent Length B 4 in 100 mm or 110 mm 1 4 in 100 mm or 1...

Page 19: ...ain at least 6 ft 1 8 m spacing between terminal and adjoining wall of inside corner h Locate bottom of vent terminal at least 7 ft 2 1 m above a public walkway i Maintain minimum clearance of at least 4 ft 1 2 m 3 ft 900 mm in Canada horizontally between vent terminal and gas meters electric meters regulators and relief equipment Do not install vent terminal above or below this equipment j Do not...

Page 20: ...t boiler vent terminals Maintaining greater spacing is recommended to avoid frost damage to building surfaces where vent terminations are placed q For multiple boiler installations with vertical roof terminals maintain minimum 12 in 300 mm horizontal distance between adjacent boiler vent terminals B CPVC PVC Venting WARNING Asphyxiation Hazard Failure to follow these instructions could cause produ...

Page 21: ...e 6B c See Table 7C for CPVC PVC installer provided vent and combustion air components required for optional vertical roof terminals shown in Figure 7 2 Field Installation of CPVC PVC Two Pipe Vent System Connector Refer to Figure 9 and following steps Vent Components Quantity APX425 APX525 Horizontal Snorkel Termination 4 in APX625 APX725 APX825 Horizontal Snorkel Termination 6 in Schedule 40 PVC...

Page 22: ... a Models APX425 and APX525 only Apply supplied dielectric grease grease pouch attached to two pipe vent connector to gasket WARNING Asphyxiation Hazard Models APX425 and APX525 only Apply supplied dielectric grease to gasket inside vent section of two pipe vent connector Failure to apply the grease could result in flue gas leaks from gasket rupture during vent pipe installation or gasket deterior...

Page 23: ...he worm band clamp screw For models APX625 APX725 and APX825 Apply supplied red RTV silicon sealant at least 1 in 25 mm wide around circumference of installer provided 6 in Schedule 40 PVC combustion air pipe at end to be inserted into vent connector Figure 10 Near Boiler Vent Combustion Air Piping f Clean all vent and combustion air pipe joints with primer and secure with transition cement 4 oz b...

Page 24: ...n 1680 mm from the boiler as measured along the vent The wall is 12 in 300 mm thick or less Anairspaceofatleastofthatshown in Figure 12 is maintained around outside of the vent pipe to provide air circulation If above three conditions cannot be met simultaneously when penetrating a combustible wall use a single wall thimble Thermal Solutions part numbers 102181 01 4 in and 103419 01 6 in Thimble u...

Page 25: ...all another PVC 90 elbow so that elbow leg is opposite the building s exterior surface Install rodent screen and vent terminal supplied with boiler see Figure 13 for appropriate configuration Brace exterior piping if required ii Combustion Air Piping After penetrating wall install a Schedule 40 PVC 90 elbow so that elbow leg is in the up direction Install maximum vertical run of 7 ft 2 1 m of Sche...

Page 26: ...equired C Polypropylene Venting WARNING Asphyxiation Hazard Follow these instructions and the installation instructions included by the original polypropylene venting component manufacturers M G DuraVent or Centrotherm whichever applicable Failure to do so could cause products of combustion to enter the building resulting in severe property damage personal injury or death Where a conflict arises b...

Page 27: ...Hazard Vent systems made by M G DuraVent and Centrotherm Eco Systems rely on gaskets for proper sealing When these vent systems are used take the following precautions Make sure that gasket is in position and un damaged in the female end of the pipe Make sure that both the male and female pipes are free of damage prior to assembly Only cut vent pipe as permitted by the vent manufacturer in accorda...

Page 28: ...etails of chimney chase installation c Flexible polypropylene pipe must be treated carefully and stored at temperatures higher than 41 F 5 C d Do not bend or attempt to install flexible pipe if it has been stored at lower ambient temperature without allowing the pipe to warm up to a higher temperature first WARNING Asphyxiation Hazard Bending or attempting to install flexible pipe if it has been s...

Page 29: ...s and components are shown in Table 11B D Stainless Steel Venting WARNING AsphyxiationHazard Followtheseinstructions and the installation instructions included by the original stainless steel venting component manufacturers Heat Fab M G DuraVent or Z Flex whichever applicable Failure to do so could cause products of combustion to enter the building resulting in severe property damage personal inju...

Page 30: ...ystems and Vent Components Stainless Steel Figure 16 Field Installation of Two Pipe Vent System Adapter for Stainless Steel c Where the use of silicone is called for in the following instructions use GE RTV 106 or equivalent for the vent collar Seal galvanized combustion air piping sections with any general purpose silicone sealant such as GE RTV102 Seal PVC combustion air piping sections with PVC...

Page 31: ...er joint Seal outside of all joints 4 Horizontal Sidewall Vent Termination a Standard Two Pipe Termination See Figures 5A and 5B i Vent Termination Use a stainless steel tee in the upright position NOTICE The joint between the terminal and the last piece of pipe must be outside of the building Male end of terminal will fit into female end of any of the listed stainless vent systems Apply a heavy b...

Page 32: ...they will operate at maxi mum speed Do not operate a summer exhaust fan Close fireplace dampers 4 Place in operation the appliance being inspected Follow the Lighting or Operating Instructions Adjust thermo stat so appliance will operate continuously 5 Test for spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle or smoke from a ciga...

Page 33: ...inals is permitted c Do not exceed the individual boiler maximum vent length listed in Table 5 IV Venting F Multiple Boiler Installation Venting continued d For horizontal sidewall terminations maintain at least 12 in 300 mm minimum horizontal distance between any adjacent individual boiler vent terminations Additional horizontal spacing between any adjacent individual boiler vent terminations as ...

Page 34: ...34 Figure 17 Multiple Boiler Direct Vent Termination IV Venting F Multiple Boiler Installation Venting continued ...

Page 35: ...located at boiler left side below inlet and outlet water pipe connections Refer to Figures 1A 1B 1C 1D and 18 5 Condensate trap must be filled up with water prior to boiler start up and before connecting any condensate line to the boiler to insure combustion products cannot escape from operating boiler To fill the trap inject water in the amount of 1 cup 240ml through condensate trap connection Do...

Page 36: ...odes and instructions enclosed with the kit for condensate neutralizer installation 3 Limestone chips will get coated by neutral salts product of chemical reaction between limestone and acidic condensate and lose neutralizing effectiveness over time Therefore periodic condensate neutralizer maintenance and limestone chip replacement must be performed A pH test or acid test kits are available from ...

Page 37: ...Supplied Piping and Trim Installation Install these components prior to connecting boiler to system piping as follows VI Water Piping and Trim Figure 19A Factory Supplied Piping and Trim Installation APX425 and APX525 NOTICE Failure to properly pipe boiler may result in improper operation and damage to boiler or structure Install boiler so that the gas ignition system components are protected from...

Page 38: ... tee is oriented towards front of boiler and run of 3 4 NPT tee is oriented vertically VI Water Piping and Trim A Factory Supplied Piping and Trim continued Figure 19B Factory Supplied Piping and Trim Installation APX625 and APX725 e Install drain valve into tee bottom outlet f Locate and remove 2 1 in NPT x 2 in long black nipples 1 in x 1 in x in NPT black tee 1 in x 1 in x 1 in NPT black tee pa...

Page 39: ...tch kit Remove flow switch and paddles from packaging carton See Taco Instruction Sheet for Flow Switch Kit supplied with flow switch for specific details f For APX625 select paddle stamped 3 g For APX725 select paddle stamped 1 h Attach paddle to flow switch stem using supplied machine screw i Apply pipe dope to flow switch at threaded brass bushing end Then mount the switch threaded end with att...

Page 40: ...et for Flow Switch Kit supplied with flow switch for specific details l Select paddle stamped 1 for APX825 m Attach paddle to flow switch stem using supplied machine screw n Apply pipe dope to the switch threaded brass bushing end Then mount the switch threaded end with the attached paddle into 2 in x 2 in x 1 in NPT tee branch and tighten such that distance between bottom of switch housing and to...

Page 41: ...oop the system circulator must be sized to ensure that the flow through boiler stays within the defined parameters to prevent overheating when the boiler is fired at it s full rated input Install a flow meter to measure the flow or fire the boiler at full rate and ensure the boiler DT does not exceed 35 F 19 C 2 Direct connection of Apex boiler to heating system similar to a conventional boiler is...

Page 42: ... 1915 76 0 31 6 1935 Boiler Model Supply Return Connection in Near Boiler Pipe Size in ΔT 35 F ΔT 30 F ΔT 25 F ΔT 20 F Flow GPM Boiler Piping Head Loss ft Circulator Model Flow GPM Boiler Piping Head Loss ft Circulator Model Flow GPM Boiler Piping Head Loss ft Circulator Model Flow GPM Boiler Piping Head Loss ft Circulator Model APX425 1 2 21 5 6 4 UP26 64F 25 1 8 4 UP26 99F 30 2 11 5 UPS43 100F S...

Page 43: ... 2 2 1 3 Swing Check Valve 4 5 5 5 6 5 9 0 Flow Check Valve typical 54 0 74 0 57 0 177 0 Butterfly Valve 2 7 2 0 2 7 4 5 Threaded Fitting and Valve Equivalent Length Ft Fitting or Valve Description Black Threaded Pipe or Valve Size 1 1 1 2 90 Elbow 2 6 3 5 4 0 5 2 Long Radius Elbow 45 or 90 1 4 1 8 2 2 2 8 Tee through flow 1 8 2 3 2 7 3 5 Tee Branch flow 5 3 6 9 8 1 10 0 Close Return Bend 4 4 5 8 ...

Page 44: ...ter ini tial fill and eliminate any water leakage as early as possible Maintain the water pressure in the boiler at a minimum of 20 psi 140 kPa The boiler water pH must be within 7 5 pH 9 5 If the system contains any aluminum components pH must be less than 8 5 Black oxide sludge magnetite Fe3 O4 forms as the result of continuous electrolytic corrosion in any system not protected by an inhibitor S...

Page 45: ...45 Figure 20 Near Boiler Piping Heating Only VI Water Piping and Trim C Standard Installation Requirements continued ...

Page 46: ...46 Figure 21 Near Boiler Piping Heating Plus Indirect Water Heater VI Water Piping and Trim C Standard Installation Requirements continued ...

Page 47: ...ygenated side of the heat exchanger such as the pump and expansion tank must be designed for use in oxygenated water Table 15 Multiple Boiler Water Manifold Sizing Boiler Model Number of Units 2 3 4 5 6 7 8 Recommended Minimum Common Water Manifold Size NPT APX425 2 3 3 4 5 5 5 APX525 3 4 4 5 5 6 6 APX625 3 4 5 5 6 6 6 APX725 4 4 5 6 6 8 8 APX825 4 5 5 6 6 8 8 VI Water Piping and Trim D Special Si...

Page 48: ...l module boiler b Regarding an individual module boiler piping system specific details c Selection criteria for individual module boiler space heating and or DHW circulators 2 For installations where indirect domestic hot water heater is combined with space heating theAllianceSL modelmustbepipedasaseparate heatingzoneoffthesystemheader Thecirculatormust be sized based on the Alliance SL model coil...

Page 49: ...estic Hot Water Heater Page 1 of 2 VI Water Piping and Trim E Multiple Boiler Installation Water Piping continued NOTICE Installing a low water cutoff in the system piping of multiple boilers is strongly recommended and may be required by local codes ...

Page 50: ... w Domestic Hot Water Heater Page 2 of 2 VI Water Piping and Trim E Multiple Boiler Installation continued NOTICE Installing a low water cutoff in the system piping of multiple boilers is strongly recommended and may be required by local codes ...

Page 51: ... 118 95 81 72 65 60 56 52 50 0 824 360 247 199 170 151 137 126 117 110 104 1 1 049 678 466 374 320 284 257 237 220 207 195 1 1 380 1392 957 768 657 583 528 486 452 424 400 1 1 610 2085 1433 1151 985 873 791 728 677 635 600 2 2 067 4016 2760 2217 1897 1681 1523 1402 1304 1223 1156 2 2 469 6401 4400 3533 3024 2680 2428 2234 2078 1950 1842 3 3 068 11316 7778 6246 5345 4738 4293 3949 3674 3447 3256 1 ...

Page 52: ...1858 1492 1277 1131 1025 943 877 823 778 2 2 469 4308 2961 2377 2035 1803 1634 1503 1399 1312 1239 3 3 068 7615 5234 4203 3597 3188 2889 2658 2472 2320 2191 1 CFH of LP Gas is approximately equal to 2 5 MBH contact your gas supplier for the actual heating value of your gas Table 17 Equivalent Lengths of Standard Pipe Fittings Valves ft Nominal Pipe Size Inc Inside Diameter In Valves Screwed Fully ...

Page 53: ...r Natural Gas and Propane Installation Code CAN CSA B149 1 2 Use thread joint compounds pipe dope resistant to action of liquefied petroleum gas 3 Apex boilers have factory supplied miscellaneous parts cartons which include gas piping components to connect boiler gas valve s to gas supply system Install these components prior to connecting boiler to gas supply system piping as follows Boiler Model...

Page 54: ...er the boiler is piped to the gas supply and before it is fired 3 For the low and high gas pressure switches proper operation the boiler inlet gas pressure must be within the range shown in Table 19 3 The gas pressure can be measured at the gas valve inlet pressure port Refer to Figure 25 Gas Inlet Pressure Tap and Pressure Switch Location 4 If either pressure switch is tripped it must be manually...

Page 55: ...tage 24 VAC Connections see Figure 27 DANGER Electrical Shock Hazard Positively assure all electrical connections are unpowered before attempting installation or service of electrical components or connections of the boiler or building Lock out all electrical boxes with padlock once power is turned off WARNING Electrical Shock Hazard Failure to properly wire electrical connections to the boiler ma...

Page 56: ... Nominal boiler current draw is provided in Table 20 These values are for planning purposes only and represent only the boiler s power consumption To obtain total system power consumption add any selected circulator and component current draws VIII Electrical continued Model Number Nominal Current amps APX425 7 APX525 6 APX625 8 APX725 8 APX825 8 Table 20 Boiler Current Draw E Flow Switch Wiring A...

Page 57: ...57 VIII Electrical continued Figure 26 Ladder Diagram ...

Page 58: ...58 VIII Electrical continued ...

Page 59: ...59 Figure 27 Wiring Connections Diagram VIII Electrical continued ...

Page 60: ...ure 28A Modified Wiring For DHW Priority When Using Low Flow Circulator Piped Off System Header Heating with Central Heating Circulators Plus Alternately Piped Indirect Water Heater VIII Electrical continued ...

Page 61: ...T POWER SUPPLY 120 60 1 FIELD INSTALLED 40VA TRANSFORMER SEE NOTE 2 WIRE 24V THERMOSTATS W HEAT ANTICIPATOR SET AT 0 9 AMPS 40VA REQ D FOR EVERY 3 ZONE VALVES 2 WIRE 24V THERMOSTATS W HEAT ANTICIPATOR SET AT 0 5 AMPS 40VA REQ D FOR EVERY 4 ZONE VALVES 2 WIRE 24V THERMOSTATS W HEAT ANTICIPATOR SET AT 0 3 AMPS 40VA REQ D FOR EVERY 4 ZONE VALVES WHITE ROGERS 1361 102 ZONE VALVES CHECK FOR CROSS PHASI...

Page 62: ...62 Figure 29 Multiple Boiler Wiring Diagram Internal Sage2 1 Multiple Boiler Control Sequencer Three Boilers Shown Typical Connections for up to Eight Boilers VIII Electrical continued ...

Page 63: ... the Tekmar 265 Control and each boiler s Sage2 1 Control The boiler s and system supply water temperature will be reset together to maintain the input that is needed to the system When a call for Indirect Hot Water is generated to the Tekmar 265 the control will de energize the zone pump control ZC terminal energize the Indirect pump and modulate the boiler firing to establish a setpoint temperat...

Page 64: ... temperature to supply enough input to the system main to satisfy the desired reset water temperature in the main established by the Tekmar 264 Control When a call for Indirect Hot Water is generated to the Tekmar 264 the control will de energize the zone pump control ZC terminal energize the Indirect pump and sequentially fire the boilers to establish a setpoint temperature in the main for the In...

Page 65: ...or P N 101935 01 or 103104 01 A header sensor must be installed and wired to the Master Sequencer enabled Sage2 1 Controller The header sensor is installed on the common system piping and provides blended temperature information to the Sequence Master Refer to piping diagram Figure 23A on page 49 for installation location and Figure 31 or 32 for installation detail b RJ45 Splitters P N 103192 01 R...

Page 66: ... 1 through 8 WARNING When two boiler s addresses are the same undesirable simultaneous operation occurs 5 Enable 1 Boiler Master Enable only one Sage2 1 Control s Sequencer Master WARNING When more than one Sequencer Master is enable erratic behavior will result 6 Power Down All Boilers 7 Power Up Master Sequencer Enabled Boiler First 8 Power Up Other Boilers 9 Confirm Communication From the Home ...

Page 67: ...p F Prepare to check operation 1 Obtain gas heating value in Btu per cubic foot from gas supplier 2 Apex gas valves have inlet and outlet pressure taps with built in shut off screw Turn each screw from fully closed position three to four turns counterclockwise to open taps Connect manometers to pressure taps on gas valve NOTICE If it is required to perform a long term pressure test of the hydronic...

Page 68: ...68 IX System Start up continued Apex Series Operating Instructions Figure 34 Operating Instructions ...

Page 69: ...alyzer probe through flue temperature sensor silicon cap opening If required also remove the flue temperature sensor silicon cap and insert the analyzer probe directly into flue sensor port Reinstall the sensor and the cap upon combustion testing completion 2 Verify O2 or CO2 and CO are within limits specified in Table 21 natural gas or Table 22 LP gas at both high and low fire as described in the...

Page 70: ...em Start up continued a Lock boiler in high fire and allow boiler to operate for approximately 5 minutes before taking combustion readings To lock boiler in high fire from the home screen press Adjust Adjust Login 000 Enter the password 086 and press return arrow to close the keypad Press Save Adjust High to lock boiler in high fire WARNING The offset screw has been factory set using precision ins...

Page 71: ...tion to adjust the maximum modulation fan speed 10 Return boiler to normal operating mode by pressing Auto 11 Return other gas fired appliances to previous condition of use N Test Safety Limits Controls 1 Test the ignition system safety shut off by disconnecting the flame sensor connector black plug with orange wire from the flame ionization electrode See Figure 27 The boiler must shut down and mu...

Page 72: ... gas inlet pressure is between the upper and lower limits shown in Table 19 on page 53 with all gas appliances including the converted boiler both on and off WARNING Asphyxiation Hazard These instructions include a procedure for adjusting the air fuel mixture on this boiler This procedure requires a combustion analyzer to measure the O2 or CO2 and Carbon Monoxide CO levels in flue gas Adjusting th...

Page 73: ...RNING The throttle adjustment values shown in Table 24A and Table 24B are approximate The final throttle setting must be found using a combustion analyzer WARNING Asphyxiation Hazard If the throttle is very far out of adjustment on the rich counter clockwise side the boiler burner may be running at 0 excess air or even with air deficiency Operating the boiler in this condition may cause property d...

Page 74: ...selections are correct for your heating system Refer to Paragraph G Adjusting Parameters Pump Setup Menu for additional information Boiler Pump Domestic Pump 5 Contractor Setup Contractor Name Enter your contact information name address and phone number on this screen In the event of a fault or the need to adjust a setting the display will direct the homeowner to you Address Phone 6 Manual Control...

Page 75: ...ettings Outdoor air reset setpoint saves fuel by adjusting the water temperature of a heating boiler lower as the outside air temperature increases 6 Warm Weather Shutdown WWSD Some boilers are used primarily for heating buildings and the boilers can be automatically shutdown when the outdoor air temperature is warm When outside air temperature is above the WWSD setpoint this function will shut do...

Page 76: ...point 4 Outdoor Air Reset Ifanoutdoortemperaturesensorisconnectedtotheboiler and Outdoor Reset is enabled the Central Heat setpoint will automatically adjust downwards as the outdoor temperature increases When the water temperature is properlymatchedtoheatingneedsthereisminimalchance of room air temperature overshoot Excessive heat is not sent to the room heating elements by overheated supplywater...

Page 77: ...e for longer than a limit time delay the Control shuts down the boiler and delays restart If the inverted temperature is detected more than five times the boiler manual reset Hard Lockout is set This condition is the result of incorrectly attaching the supply and return piping 5 External Limit An external limit control can be installed between terminals 11 and 12 on the low voltage terminal strip ...

Page 78: ...nder of the year 6 Multiple Demands The Sequence Master responds to Central Heat DHW and frost protection demands similar to the stand alone boiler For example when selected and DHW priority is active the sequence master uses DHW setpoint Diff Above Diff Below and pump settings 7 Shared or Isolated DHW Demand When the Indirect Water Heater IWH parameter is set to Primary Piped the Sequence Master ...

Page 79: ... conducted Pre ignition Spark is energized and it is confirmed that no flame is present Direct Ignition Spark and Main fuel valve are energized Supply 132 F 140 F Rate 100 Status Setpoint Boiler 1 Priority Central Heat i Running Priority Central Heat Status Running burner On circulator s On After flame is proven normal boiler operation begins Modulation rate depending on temperature and setpoint s...

Page 80: ...vious menu or screen Repeatedly pressing the Close symbol will always return the display to the Home screen Arrow Symbol The Arrow symbol links together all screens in the selected group For example repeated pressing the right Arrow symbol will rotate the display around all the screens in the Status group Using this feature the user can review all the boiler status and adjustment mode screens Faul...

Page 81: ...trend may indicate pump speed settings need to be changed Cycles and Hours Boiler cycles and hours are used to monitor the boilers overall compatibility to the heating load Excessive cycling compared to run time hours may be an indication of pumping boiler sizing or adjustment issues Supply measured supply water temperature This is the temperature being used to start stop and fire boiler when ther...

Page 82: ... Screens Detail screens are accessed by selected the Detail button from the Home screen and provide in depth operating parameter status such as On Point Off Point and Setpoint Source information Demand detail screens are provided for Central Heat shown DHW and Sequencer demands OutdoorResetsavesenergyandimproveshomecomfort by adjusting boiler water temperature This screen presents the active reset...

Page 83: ... for boiler address 1 is provided as follows 1 Boiler 1 is connected to the network 1 Blinking underline boiler 1 is starting 1 Solid underline boiler 1 is running Networked Boilers Boiler 1 Lead 50 Firing Boiler 2 50 Firing Boiler 3 0 Available Boiler 4 0 Available i The Networked Boilers screen is selected by pressing the Detail button from the Home screens and pressing Networked Boilers from th...

Page 84: ...er Password required Installer Password 76 Warning Only Qualified Technicians Should Adjust Controls Contact Your Qualified Heating Professional i Press 5 digit display to Input Password Press Save to enter password i 000 1 CL R ES C 5 4 3 2 6 B S 0 9 8 7 Press 5 digit display to Input Password i 076 After inputting the password press to enter password After password is Saved These buttons access ...

Page 85: ...is not monitored for faults Wired Outdoor Sensor is installed directly on the boiler terminal Strip TB2 Wireless Outdoor sensor is installed and wireless Enabled Enable Disable Frost Protection Disable Frost Protection is not used Enable Boiler and system circulators start and boiler fires when low outside air supply and return temperatures are sensed as follows 0 Secs 0 900 Secs Anti Short Cycle ...

Page 86: ...he boiler change the Central Heat Maximum Modulation fan speed setting to limit the boiler output accordingly See Table 28 Minimum to Maximum Modulation Domestic Hot Water DHW Max Modulation This parameter defines the highest modulation rate the Control will go to during a Domestic Hot Water call for heat If the rated input of the indirect water heater is less than the maximum output of the boiler...

Page 87: ...o maintain flow through boiler within limits shown in Table 12 Pump Runs during central heat and frost protection call for heat Pump does not start for a DHW call for heat and will be forced off if there is a DHW call for heat and Domestic Hot Water Priority is active Primary Loop Pipe IWH Never Primary Loop Piped IWH Boiler Piped IWH Domestic Pump run pump for Activates the Domestic pump output a...

Page 88: ...em pump X DHW pump X Boiler Pump X X Sequencer Master Parameter Selections Sequencer Master Enabled Indirect Water Heater Boiler Piped Pump Parameter Selections System Pump Central Heat No Priority Never Boiler Pump Central Heat Off DHW Priority Any demand DHW Pump Boiler Piped IWH Never Explanation Make sure indirect water heater and DHW pump are sized to maintain flow though boiler within limits...

Page 89: ...ter call for heat Domestic hot water priority is optional It is permissible for the domestic and system pumps to run at the same time The boiler pump must run for every call for heat Example Pump Parameter selections continued Multiple Boilers IWH piped to primary system pump required to run for any call for heat Sequencer Master Boiler 1 Boiler 2 Wiring locations Thermostat X DHW call for heat X ...

Page 90: ...High Auto Low NOTE Selecting Low or High locks manual mode firing rate at min or max Rate After combustion testing select Auto to return the boiler to normal operation Press Auto to return firing rate to Automatic Mode Press Low to select manual firing rate control and Minimum firing rate Manual Speed Control i Press High to select manual firing rate control and Central Heat Maximum firing rate Us...

Page 91: ...C 80 F to 190 F 26 7 C to 87 8 C Domestic Hot Water Setpoint The Domestic Hot Water DHW Setpoint parameter is used to create a minimum boiler water temperature setpoint that is used when DHW heat demand is on When the DHW heat demand is not on the contact is open or not wired this setpoint is ignored 160 F 71 1 C 80 F to 190 F 26 7 C to 87 8 C Domestic Hot Water Thermostat Sleep or Away Setback Se...

Page 92: ... the heat loss calculation It is typically set to the coldest outdoor temperature 70 F 21 1 C 32 F to 100 F 0 C to 37 8 C High Outdoor Temperature The High Outdoor Temperature parameter is the outdoor temperature at which the Low Boiler Water Temperature is supplied This parameter is typically set to the desired building temperature 110 F 43 3 C 70 F to 190 F 21 1 C to 87 8 C Low Boiler Water Temp...

Page 93: ...et Curve Outdoor Air Temperature 20 10 5 15 10 5 0 110 45 40 20 25 30 35 55 60 65 70 15 50 145 115 150 120 140 135 130 125 155 190 160 195 165 185 180 175 170 200 Boost Maximum Off Point Central Heat Setpoint minus Diff Above Low Boiler Water Temp Default 110 F High Outside Air Temp Default 70 F 10 F Hot Water Setpoint Minimum Water Temperature Default 130 F TOD Setback Setpoint Default 170 F Cent...

Page 94: ... goes to DHW Service Primary Piped The Sequence Master responds to the DHW Call For Heat This allows one or more boilers to provide heat to the IWH Disabled Enable Disable DHW Two Boiler Start The Sequencer to immediately start two boilers for a DHW call for heat Used when DHW is the largest demand Only visible when primary piped IWH is selected 120 Secs 120 1200 Secs Boiler Start Delay Slave boil...

Page 95: ... loose fitting clothing 3 Gloves 4 Eye Protection Take steps to assure adequate ventilation Wash all exposed body areas gently with soap and water after contact Wash work clothes separately from other laundry and rinse washing machine after use to avoid contaminating other clothes Discard used RCF components by sealing in an airtight plastic bag RCF and crystalline silica are not classified as haz...

Page 96: ...alled on the heating system to prevent damage if the boiler is inoperative Burn Hazard This boiler contains very hot water under high pressure Do not unscrew any pipe fittings nor attempt to disconnect any components of this boiler without positively assuring the water is cool and has no pressure Always wear protective clothing and equipment when installing starting up or servicing this boiler to ...

Page 97: ...e every year 1 Test the flow switch by disabling the boiler primary loop circulator The boiler must not start when there is not water flow 2 Follow the procedure for turning the boiler off per Figure 34 Operating Instructions 3 Inspect the wiring to verify the conductors are in good condition and attached securely DANGER Explosion Hazard Electrical Shock Hazard Burn Hazard This boiler uses flammab...

Page 98: ... removal initial boiler cleaning from copper dust flux residue and any boiler debris and for preventive treatment as corrosion scale inhibitors i Fernox Restorer universal cleaner sludge remover scale remover flux residue debris remover corrosion inhibitor ii Fernox Protector Alphi 11 CH Copal sludge remover corrosion inhibitor Follow manufacturer application procedure for proper heating system bo...

Page 99: ...ath E CondensateOverflowSwitchandCondensate Trap Removal and Replacement For removal or replacement of the condensate overflow switch and or condensate trap follow the steps below For parts identification refer to Section XIII Repair Parts 1 Condensate Overflow Switch Removal and Replacement a Disconnect power supply to boiler b Remove2wirenutsanddisconnectoverflowswitch wire pigtails from boiler ...

Page 100: ...97 248 120 386 e Using pliers release spring clip securing the overflowswitchtocondensatetrapbodyandremove theswitch Notethattheswitchhasfactoryapplied siliconadhesiveseal whichmayhavetobecarefully cut all around to facilitate the switch removal f Usingpliers releasespringclipsecuringcondensate trap body to the heat exchanger bottom drain connection g First pull the trap downwards to release from ...

Page 101: ...select flashing buttons to be directed to the Fault cause B Display Faults Figure 43 Help Menu Indication Condition Possible Cause Display Completely Dark Fan off LWCO lights off no green power light on Control No 120 VAC Power at Boiler Check breaker and wiring between breaker panel and boiler Display Completely Dark Fan running No 24 VAC Power to Control Loose defective 120Vac connection wiring ...

Page 102: ...pen or closed graphically represents each safety limit and flow switch The closed contact icon is steady the open contact icon is blinking For example the screen shown to the left illustrates a closed Air Pressure Switch contact and an open Auto Reset High Limit contact The Auto Reset High Limit is causing the boiler to stop firing NOTE Since the limit string items are wired in series all limits d...

Page 103: ...for Hard Lockout 4 Loose wiring to limit device External Limit defective or jumper not installed Low Gas Pressure Switch contact open if installed Flow switch not installed and jumper missing No flow or insufficient flow through boiler loop or flow switch defective If neither yellow or green light is on check LWCO harness 7 Return sensor fault Shorted or open return temperature sensor Shorted or m...

Page 104: ...lower speed harness Defective blower 19 Purge rate proving failed Blower is not running at Purge rate when it should or blower speed signal not being detected by Sage2 1 Loose connection in 120 VAC blower wiring Loose or miswired blower speed harness Defective blower 20 Invalid Safety Parameters Unacceptable Sage2 1 control Safety related parameter detected Safety Parameter verification required C...

Page 105: ...105 ...

Page 106: ...ns representatives or outlets Should you require assistance in locating a Thermal Solutions representative or outlet in your area or have questions regarding the availability of Thermal Solutions products or repair parts please contact Thermal Solutions Customer Service at 717 239 7642 or Fax 877 501 5212 ...

Page 107: ...ot shown 806603061 XIII Repair Parts continued Burner Components Key No Description Part Number APX425 APX525 APX625 APX725 APX825 1K Replacement Burner Kit includes burner burner head seal and hardware 104988 01 104989 01 104990 01 104991 01 1L Replacement Burner Door Kit includes door burner door inner and outer seals gaskets for sensor and ignitor insulation and thermostat does not include igni...

Page 108: ...Natural Gas 105001 02 103223 01 LP Gas 105000 01 LP Gas 105000 02 2D Blower Inlet Replacement Kit includes swirl plate blower adapter plate and mounting hardware 104620 04 104620 05 N A N A N A 2E Replacement Gas Valve Kit includes one gas valve and o rings 105004 01 105004 02 Natural Gas 105004 04 LP Gas 105004 03 2F Gas Valve Flange Kit includes one 90 gas valve flange o ring and hardware N A 10...

Page 109: ...109 XIII Repair Parts continued APX625 APX725 and APX825 APX825 shown ...

Page 110: ...itch Kit includes float switch and clamp 105005 01 3C Spring Hose Clamp 15 16 in OD hose 101632 01 3D Rubber Grommet Condensate Trap 101595 01 3E Condensate Neutralizer Kit not shown includes limestone chips 101867 01 3F Limestone Chips 2 lb bag not shown 101873 01 3G Air Pressure Switch 104426 01 3H Air Pressure Switch Tubing Silicone 3 16 in ID x 0 07 in Wall Thickness 13 5 in 7016041 22 in 1027...

Page 111: ...625 APX725 APX825 4A Replacement Sage2 1 Control programmed 104472 01 104472 04 Natural Gas 105008 02 104472 04 LP Gas 105008 01 4B Replacement Display programmed includes mounting hardware 104779 01 4C Transformer 102516 01 103193 01 4D Upper Front panel 102778 01 4E Control Slide Out Tray 103336 01 ...

Page 112: ...112 XIII Repair Parts continued APX425 and APX525 ...

Page 113: ...n x 8 in includes gasket 105010 01 5H Replacement Access Panel Kit 5 in x 16 in includes gasket N A 105011 01 5J Access Panel Gasket 5 in x 8 in 102877 01 5K Access Panel Gasket 5 in x 16 in N A 102613 01 5L Replacement Handle Kit includes gasket 105015 01 5M Gas Train Bracket N A 102611 01 5N Nylon Glide Replacement Kit includes 6 glides 105014 01 5O Replacement Door Latch Kit includes rivets 105...

Page 114: ...114 XIII Repair Parts continued APX625 APX725 and APX825 ...

Page 115: ...ment Access Panel Kit 5 in x 8 in includes gasket 105010 01 5H Replacement Access Panel Kit 5 in x 16 in includes gasket N A 5J Access Panel Gasket 5 in x 8 in 102877 01 5K Access Panel Gasket 5 in x 16 in N A 5L Replacement Handle Kit includes gasket N A 5M Gas Train Bracket 103240 01 5N Nylon Glide Replacement Kit includes 6 glides 105014 01 5O Replacement Door Latch Kit includes rivets 105012 0...

Page 116: ...sure Switch Wire Harness N A 102704 01 6F Flow Switch Kit not shown includes switch and paddles 104927 01 6G Flow Switch Repair Paddle Kit not shown includes paddles and hardware 104926 01 6H Outdoor Temperature Sensor not shown 102946 01 6J Header Sensor for Direct Immersion 1 2 in NPT not shown 101935 01 6K Header Sensor Kit not shown includes mounting hardware 103104 01 6L 30 in Long Schedule 4...

Page 117: ...ss includes 10A 10B 10C 10D 102701 02 10A Main Low Voltage Harness 103009 02 10B High Voltage Harness 103010 02 10C Blower Power Harness 103012 01 10D Communication Harness 103011 01 10E Igniter Harness 103486 01 10F Wiring Harness Thermal Link and Burner Door Thermostat 104574 01 XIII Repair Parts continued ...

Page 118: ... Air Piping Figure 11 24 CPVC PVC Expansion Loop and Offset Figure 12 24 Wall Penetration Clearances for PVC Vent Pipe Figure 13 25 Rodent Screen Installation Figure 14 28 Vent System Field Modification to Install PVC to PP Adapter M G DuraVent Shown Figure 15 29 Flexible Vent in Masonry Chimney with Separate Combustion Air Intake Figure 16 30 Field Installation of Two Pipe Vent System Adapter for...

Page 119: ... Sage2 1 Multiple Boiler Control Sequencer Three Boilers Shown Typical Connections for up to Eight Boilers Figure 30A 63 Multiple Boiler Wiring Diagram w Tekmar 265 Control Figure 30B 64 Multiple Boiler Wiring Diagram w Tekmar 264 Control Figure 31 65 Recommended Direct Immersion Header Sensor Installation Detail Figure 32 65 Alternate Immersion type Header Sensor Installation Detail Figure 33 66 ...

Page 120: ... 26 Listed Polypropylene Vent System Manufacturers Table 10A 27 Listed Polypropylene Pipe Fittings and Terminations M G DuraVent Table 10B 27 Listed Polypropylene Pipe Fittings and Terminations Centrotherm Eco Table 11A 30 Thermal Solutions Vent System Components Stainless Steel Table 11B 30 Alternate Vent Systems and Vent Components Stainless Steel Section VI Water Piping and Trim Table 11C 35 Ma...

Page 121: ...urns for LP Conversion Table 24A 73 Approximate Throttle Screw Adjustment Values from Fully Closed Position Natural Gas Table 24B 73 Approximate Throttle Screw Adjustment Values from Fully Closed Position LP Gas Section X Operation Table 25 76 Order of Priority Table 26 77 Frost Protection Table 27 79 Boiler Sequence of Operation Table 28 86 Parameters Changed Using the Boiler Type Parameter Selec...

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Page 124: ...eration through a heat exchanger or a combination for such purposes and do not apply to residential grade products or industrial uses 2 Components Manufactured by Others Upon expiration of the one year limited warranty on commercial grade boilers all boiler components other than heat exchangers manufactured by others butfurnished byThermal Solutions such as circulator and controls will be subject ...

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