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Burnham K2WT Residential, Installation, Operating And Service Instructions

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Burnham K2WT Residential Installation, Operating And Service Instructions Download Page 168

168

107672-03 - 5/18

U.S. Boiler Company, Inc.

P.O. Box 3020

Lancaster, PA   17604

1-888-432-8887

www.usboiler.net

Summary of Contents for K2WT Residential

Page 1: ...tion consult a qualified installer service agency or the gas supplier This boiler requires a special venting system Read these instructions care fully before installing 9700609 Installation Operating and Service Instructions for Condensing High Efficiency Direct Vent Gas Fired Water Boiler K2WTTM Residential As an ENERGY STAR Partner U S Boiler Company has determined that the K2WT Series meets the...

Page 2: ...e replaced they must be replaced with identical models Read understand and follow all the instructions and warnings contained in all the sections of this manual If any electrical wires are disconnected during service clearly label the wires and assure that the wires are reconnected properly Never jump out or bypass any safety or operating control or component of this boiler Assure that all safety ...

Page 3: ... in the supply piping See the System Piping Section of this manual for details This boiler is supplied with safety devices which may cause the boiler to shut down and not re start without service If damage due to frozen pipes is a possibility the heating system should not be left unattended in cold weather or appropriate safeguards and alarms should be installed on the heating system to prevent da...

Page 4: ...als carbon monoxide nitrogen oxides and or other toxic or harmful substances that can are hazardous to health and life and that are known to the State of California to cause cancer birth defects and other reproductive harm INSTALL ALL GUARDS cover plates and enclosures before operating the boiler SIZE THE BOILER PROPERLY relative to the design heat load or if using domestic hot water priority the ...

Page 5: ...k Polyflue Vent Systems 55 H Assembly of Centrotherm InnoFlue Vent Systems 59 I Assembly of Stainless Steel Vent Systems 63 J Condensate Trap and Drain 65 K Removing An Existing Boiler From Common Chimney 66 VIII Gas Piping 67 IX System Piping 69 A General System Piping Precaution 69 B Standard Piping Installation Requirements 70 C Near Boiler Piping Design 72 D Piping For Special Situations 81 X ...

Page 6: ...lly with combustion air supplied from outdoors It is not designed for use in gravity hot water systems or systems containing significant amounts of dissolved oxygen I Product Description 15 A SEE TABLE 2 3 26 1 8 INSIDE OF WALL SERVICE ACCESS PANEL SUPPLY WATER CONNECTION TEMPERATURE PRESSURE GAUGE DRAIN VALVE RETURN WATER CONNECTION OUTSIDE OF WALL GAS CONNECTION RELIEF VALVE VENT CONNECTION COND...

Page 7: ...epends upon installation by a professional heating contractor in strict accordance with this manual and the requirements of the authority having jurisdiction In the absence of an authority having jurisdiction installation must be in accordance with this manual and the National Fuel Gas Code ANSI Z223 1 In Canada installation must be in accordance with the B149 1 Installation Code Where required by...

Page 8: ...should be located so as to minimize the length of the vent system 6 Thecombustionairpipingmustterminatewhereoutdoorairisavailableforcombustionandawayfromareas that will contaminate combustion air Avoid areas near chemical products containing chlorine chloride based salts chloro fluorocarbons paint removers cleaning solvents and detergents III Before Installing continued Model Size LP Conversion Ki...

Page 9: ...107672 03 5 18 Figure 4 1 Minimum Clearances To Combustible Construction IV Locating the Boiler continued LEFT SIDE CLEARANCE MAY BE REDUCED TO 1 2 HOWEVER RELIEF VALVE MUST REMAIN IN SAME SPACE AS BOILER ...

Page 10: ...te holes A and B Make sure that the horizontal centerline of these holes is level Holes C and D may also be drilled at this time or after the boiler is hung on the wall If the 5 16 x 2 lag screws are used drill 3 16 pilot holes 6 The wall mounting hook is used to secure the boiler to the shipping pallet Remove this hook from the pallet and secure to the wall using the 5 16 x 2 lag screws and washe...

Page 11: ...11 107672 03 5 18 Figure 5 1 Wall Layout Mounting Hole Location V Mounting The Boiler continued ...

Page 12: ...12 107672 03 5 18 Figure 5 2 Boiler Mounting Bracket Installation Boiler Wall Mounting V Mounting The Boiler continued ...

Page 13: ...other appliances provide adequate air for combustion and or ventilation air in accordance with the manufacturer s installation manual or applicable code VI Air for Ventilation Outdoor combustion air must be piped to the air intake Never pipe combustion air from areas containing contaminates such as swimming pools and laundry room exhaust vents Contaminated combustion air will damage the boiler and...

Page 14: ...ly as permitted in this manual All PVC must be listed to ASTM D2665 At least 30 of CPVC pipe and at least one CPVC elbow must be installed between the boiler s vent connection and the PVC pipe Use of foam core PVC is not permitted for venting PVC vent pipe may not be used to vent this boiler in Canada Asphyxiation Hazard Failure to vent this boiler in accordance with these instructions could cause...

Page 15: ...15 107672 03 5 18 Figure 7 0c Split Venting VII Venting A Vent System Design continued Figure 7 0a Horizontal Twin Pipe Figure 7 0b Vertical Twin Pipe BOILER ...

Page 16: ...n addition to the first 90 elbow If more elbows are desired the maximum allowable vent length must be reduced by the amount shown in Table 7 1B for each additional elbow used Termination fittings are never counted It is recommended that all field supplied PVC or CPVC elbows be 1 4 Bend Sanitary 90 Elbow or Long Sweep 1 4 Bend type elbows Figure 7 2 In this manual sanitary and long sweep elbows are...

Page 17: ...tible construction Vent 1 4 also observe clearances through both combustible and non combustible walls see 9 Air Intake 0 Concentric Portion of Concentric Terminals 0 6 Pitch of Horizontal Vent Piping Pitch all horizontal vent piping so that any condensate which forms in the piping will run towards the boiler Pitch CPVC PVC vent piping 1 4 per foot Pitch Polypropylene vent piping 5 8 per foot For ...

Page 18: ...or CPVC PVC pipe design the vent system shall allow 3 8 of thermal expansion for every 10ft of CPVC PVC pipe The boiler will always act as an anchor to one end of the vent system If at all possible select and install hangers and wall thimbles so that the vent system can expand towards the terminal When a straight run of pipe exceeds 20ft and must be restrained at both ends an offset or expansion l...

Page 19: ...19 107672 03 5 18 VII Venting A Vent System Design continued Figure 7 3 Expansion Loops for CPVC PVC Pipe Figure 7 3b Figure 7 3a Figure 7 4 Wall Penetration Clearances for PVC Vent Pipe Figure 7 3c ...

Page 20: ...may not be snorkeled Terminal Option B Ipex Low Profile Terminal Acceptable for Vent Options 1 2 This terminal is shown in Figure 7 7 If the terminal is oriented vertically alternate orientation shown in Fig 7 7 the exhaust opening must be on the top as shown See Section VII E of this manual and the Ipex instructions provided with the terminal for installation details Terminal Option C DiversiTech...

Page 21: ...r ISEP0239 w screen ISEP03 or ISEP0339 w screen Intake Elbow w screen Note 3 Elbow w screen Note 3 Elbow w screen Elbow w screen Elbow w screen Elbow w screen Elbow w screen Elbow w screen Terminal Option B Ipex Low Profile Ipex 196984 Ipex 196985 Not Permitted Not Permitted Not Permitted Not Permitted Not Permitted Not Permitted Terminal Option C DiversiTech HVENT HVENT 2 HVENT 3 Not Permitted No...

Page 22: ...ors and relief equipment Do not install vent terminal over this equipment In Canada refer to B149 1 Installation Code for clearance to meters regulators and relief equipment Do not locate the vent terminal under decks or similar structures Top of terminal must be at least 24 below ventilated eves soffits and other overhangs In no case may the overhang depth exceed 48 Where permitted by the authori...

Page 23: ...equirements Unique to Horizontal Twin Pipe Venting Systems continued PITCH INTAKE AWAY FROM BOILER IF POSSIBLE BOILER ROOM PVC AIR INTAKE PIPE CPVC VENT PIPE FIRST 30 ELBOW PVC VENT PIPE PITCH VENT PIPE 1 4 PER FOOT TOWARDS BOILER BUILDING EXTERIOR ALTERNATE ORIENTATION PITCH INTAKE AWAY FROM BOILER IF POSSIBLE 3 PVC AIR INTAKE PIPE CPVC VENT PIPE FIRST 30 ELBOW PVC VENT PIPE PITCH VENT PIPE 1 4 P...

Page 24: ...uravent PolyPro Horizontal Venting with Concentric Terminal Vent Options 3 4 Terminal Option F VII Venting B Design Requirements Unique to Horizontal Twin Pipe Venting Systems continued PITCH INTAKE AWAY FROM BOILER IF POSSIBLE BOILER ROOM PVC AIR INTAKE PIPE BUILDING EXTERIOR PITCH VENT PIPE 5 8 PER FOOT TOWARDS BOILER 2 OR 3 DURAVENT POLYPRO VENT PIPE ...

Page 25: ...ntal Twin Pipe Venting Systems continued Note Air intake termination not shown Figure 7 11 Location of Vent Terminal Relative to Windows Doors Grades Overhangs Meters and Forced Air Inlets Two Pipe System Vent Terminal Shown Two Pipe System Air Intake Terminal Not Shown ...

Page 26: ...ens is generally recommended for both terminations Two rodent screens are included within the available 2 and 3 vent kits or can be fabricated from 1 2 stainless steel mesh screen Rodent screens and are installed as shown in Figure 7 29 Rodent screens bird guards for PolyPro Polyflue and InnoFlue are as follows Size Vent System Rodent Screen Bird Guard 2 PolyPro DuraVent 2PPS BG 3 PolyPro DuraVent...

Page 27: ... 3PPS 36B w Screen 2PF 10UV or 2PF 39UV w Screen 3PF 10UV or 3PF 39UV w Screen ISEP02 or ISEP0239 w Screen ISEP03 or ISEP0339 w Screen Intake 180 Elbow w Screen 180 Elbow w Screen 180 Elbow w Screen 180 Elbow w Screen 180 Elbow w Screen 180 Elbow w Screen 180 Elbow w Screen 180 Elbow w Screen Terminal Option I Ipex FGV Concentric Ipex 196105 Note 3 Ipex 196006 Note 3 Not Permitted Not Permitted No...

Page 28: ...ft Vent Manufacturer s PN for Flex Termination Components Required 2PPS VFT 2PPS BV 2PPS FLEX 3PPS VFT 3PPS BV 3PPS FLEX IFBK02 IAWP02B IFBK03 IAWP03B Specify size of B vent e g 2PPS BV6 is for use with 6 B vent Specify length in feet Specify Flex length and B vent diameter e g IFBK022505 includes 25ft of flex and used with 5 B vent Note 1 Max vent lengths shown also apply to the intake Flex vent ...

Page 29: ...d from an outside wall see Section VII D for additional details All venting is Polypropylene supplied by the vent manufacturer shown in Table 7 13b The portion of this venting within the B vent is flexible All flex pipe must be installed vertically Up to two offsets four bends may be made in the vertical run of flex pipe Bends used to make these offsets may not exceed 45 degrees Because the flex p...

Page 30: ...trotherm InnoFlue Flex 2 0 ft 2 Selkirk Polyflue 2 0 ft 3 DuraVent PolyPro Flex 2 0 ft 3 Centrotherm InnoFlue Flex 2 3 ft 3 Selkirk Polyflue 2 3 ft 3 Duravent FasNSeal Flex 1 0 ft B Vent Air Chase 1ft 2 Flex Vent in 5 or larger B Vent 1 0 ft 3 Flex Vent in 6 or larger B Vent 1 0 ft Note Up to four 45 degree bends may be made in flex pipe or air chase These bends are not counted when figuring equiv...

Page 31: ...VC PVC Venting Vent Options 10 11 Terminal Option H Figure 7 16 Vertical CPVC PVC Venting with IPEX Concentric Vent Terminal Vent Options 10 11 Terminal Option I J VII Venting C Design Requirements Unique to Vertical Venting Systems continued ...

Page 32: ...rotherm InnoFlue Vertical Single Wall PP Venting Vent Options 12 17 Terminal Option H Figure 7 18 Duravent PolyPro Vertical Venting with Concentric Terminal Vent Options 12 13 Terminal Option J VII Venting C Design Requirements Unique to Vertical Venting Systems continued ...

Page 33: ... Venting C Design Requirements Unique to Vertical Venting Systems continued Figure 7 19 Duravent PolyPro B Vent Air Chase System Vent Options 18 19 Figure 7 20 Centrotherm InnoFlue B Vent Air Chase System Vent Options 20 21 ...

Page 34: ...ke Terminal Location Observe the following limitations on the intake terminal location also see Figures 7 22 7 23 7 24a and 7 25a The bottom of all terminals must be at least 12 above the normal snow line In no case should they be less than 12 above grade level If possible install the intake terminal on a wall away from the prevailing wind Reliable operation of this boiler cannot be guaranteed if ...

Page 35: ... 7 25a When using this option observe the following requirements When a masonry chimney containing multiple flues is used as a chase the flexible stainless vent installation is permitted through an adjacent UNUSED flue providing local authority having jurisdiction approves such installation Figure 25b Masonry chimney used as a chase must be structurally sound and in good repair All venting is stai...

Page 36: ...ft 135ft 180 135ft 135ft 135ft Rigid Vent Terminals Vent Coupling w Screen Coupling w Screen 2PPS 12B or 2PPS 36B w Screen 3PPS 12B or 3PPS 36B w Screen 2PF 10UV or 2PF 39UV w Screen 3PF 10UV or 3PF 39UV w Screen Intake 90 Elbow w Screen 90 Elbow w Screen 90 Elbow w Screen 90 Elbow w Screen 90 Elbow w Screen 90 Elbow w Screen Flex Termination Components Masonry Chimney Chase Note 3 Vent Not Permit...

Page 37: ... Chimney Chase Note 3 Vent Not Permitted 2PPS FK 2PPS FLEX 3PPS FK 3PPS FLEX 2PF FLEX KIT 2PF FLEX 3PF FLEX KIT 3PF FLEX Intake 90 Elbow w Screen 90 Elbow w Screen 90 Elbow w Screen 90 Elbow w Screen Flex Termination Components B Vent Chimney Chase Vent Not Permitted 2PPS VFT 2PPS BF 2PPS FLEX 3PPS VFT 3PPS BF 3PPS FLEX 2PF 10UV or 2PF 39UV w Screen 2PF BVSC Note 3 3PF 10UV or 3PF 39UV w Screen 3P...

Page 38: ...bow w Screen 90 Elbow w Screen 90 Elbow w Screen Flex Termination Components B Vent Chimney Chase Vent IFBK02 IFBK03 Not Permitted Intake 90 Elbow w Screen 90 Elbow w Screen Specify size of B vent e g 2PPS BV6 is for use with 6 B vent Specify length in feet Specify Flex length and B vent diameter e g IFBK022505 includes 25ft of flex and used with 5 B vent Note 1 Max vent lengths shown also apply t...

Page 39: ...plit Vent Systems continued Figure 7 22 Split Rigid Vent System Vent Options 25 32 Figure 7 23 Split Vent System Flex in B Vent Chase Vent Options 33 38 PVC AIR INTAKE PIPE FIRE STOP LISTED FOR USE WITH VENT SYSTEM PITCH 1 4 PER FT TOWARDS TRAP PVC AIR INTAKE PIPE ...

Page 40: ...doned Masonry Chimney Vent Options 33 38 CLEAN TIGHT UNUSED CHIMNEY BASE SUPPORT AND ELBOW FOR PPs FLEX PIPE EXTERIOR WALL PLATE PVC AIR INTAKE PIPE DURAVENT POLYPRO VENT PIPE OUTSIDE WALL PPs FLEX PVC ELBOW WITH RODENT SCREEN NORMAL SNOW LINE ABOVE GROUND LEVEL EXHAUST NOTE DURAVENT POLYPRO FLEX COMPONENTS SHOWN 10 OR LESS 12 MIN BOILER ...

Page 41: ... to Split Vent Systems continued Figure 7 24b Flexible PP Masonry Chimney Chase Requirements WITH CROWN 45 MAX BOILER CHIMNEY AND FOUNDATION ARE STRUCTURALLY SOUND BOILER WARNING Venting of Other Appliances Or Fireplace into Chase or Adjacent Flues Prohibited ...

Page 42: ...Unique to Split Vent Systems continued Figure 7 25a Split Vent Systems SS Flex in Abandoned Masonry Chimney Vent Option 39 Figure 7 25b Flexible SS Masonry Chimney Chase Requirements WARNING Venting of Other Appliances Or Fireplace into Chase Prohibited ...

Page 43: ...e transitioning to PVC If 3 PVC is used the first piece of PVC will either be connected to the CPVC elbow or the end of a section of CPVC vent pipe In the latter case a PVC coupling may be used to connect the first piece of PVC to the last piece of CPVC f Clean all CPVC and PVC components with the appropriate primer before cementing Cement the vent system together starting at the boiler and follow...

Page 44: ...t side of the air intake adapter Insert the first piece of PVC air intake pipe into the air intake connection and drill a 1 8 tap hole into the PVC which lines up with the 7 32 clearance hole and secure them together with a 10 x 1 sheet metal screw Seal the joint between the intake pipe and the adaptor with RTV b All intake piping may be PVC c There is a 0 minimum clearance between the air intake ...

Page 45: ...be installed between them Figure 7 29 If a 180 bend is used install a rodent screen in the open side of the bend using a ring made of PVC pipe If desired the termination fittings can be attached to the end of the vent and or intake pipes with field supplied stainless steel screws so that they can be later removed for cleaning and inspection If this is done drill a clearance hole in these fittings ...

Page 46: ... of IPEX FGV or DiversiTech CVENT Concentric Vent Terminal Terminal Options D E I J This terminal may be used for either horizontal or vertical venting See Figure 7 33 for horizontal installation or Figure 7 34 for vertical installation When PVC is used for venting a 30 CPVC straight section and CPVC elbow must be used prior to connection of the vent system to this terminal If the vent system is t...

Page 47: ...3 5 18 Figure 7 31 Installation of DiversiTech Low Profile Terminal Through Sidewall Figure 7 30 Installation of IPEX Low Profile Terminal Through Sidewall VII Venting E Assembly of CPVC PVC Vent Systems continued ...

Page 48: ...5 18 VII Venting E Assembly of CPVC PVC Vent Systems continued Figure 7 33 Installation of IPEX and DiversiTech Concentric Terminal through Sidewall Figure 7 32 Cutting IPEX and DiversiTech Concentric Vent Terminals ...

Page 49: ...ipe with the supplied stainless steel screw and nut so that it can be later removed for cleaning and inspection If this is done drill a 3 16 clearance hole in the rain cap and inner pipe in the location shown on Figure 7 32 for the size terminal kit being used and affix screw and nut Do not overtighten A field supplied rodent screen may also be installed on the end of the rain cap i For vertical i...

Page 50: ...gasket with water Slide a locking band over the male end of the pipe to be joined as shown in Figure 7 35 Push the male end of the next section of pipe into the bell until it bottoms out then back out 1 4 5 8 to provide room for thermal expansion Push barb on locking band over the bell end of the first section of pipe as shown in Figure 7 35 d Assemble the rest of the vent system per the manufactu...

Page 51: ...talled on the top of the air intake pipe If two 90 elbows are used a rodent screen can be installed between them Figure 7 37 If a 180 bend is used install the rodent screen in the open side of the bend using a ring made of PVC pipe If desired the termination fittings can be attached to the end of the intake pipes with field supplied stainless steel screws so that they can be later removed for clea...

Page 52: ...Installation of Duravent PolyPro UV Resistant Single Wall Horizontal Terminal Figure 7 37 Installation of Duravent PolyPro UV Resistant Single Wall Vertical Terminal VII Venting F Assembly of DuraVent PolyPro Vent Systems continued ...

Page 53: ...e e Seal the termination to the exterior wall plate with weather resistant RTV f Slide the interior wall plate over the termination and attach to the wall from inside the room g Attach the interior wall plate to the termination with the provided hardware h Install gaskets into co linear adapter i Attach co linear adapter to horizontal termination and orient so that the side outlet on the adapter i...

Page 54: ...e 7 39 Installation of Duravent PolyPro Concentric Vent Terminal Through Sidewall VII Venting F Assembly of DuraVent PolyPro Vent Systems continued Figure 7 40 Installation of Duravent PolyPro Concentric Terminal Through Roof ...

Page 55: ...ance hole in the cap for the male threads Secure the adaptor to the cap using a 2 or 3 electrical conduit lock nut Seal all joints with RTV G Assembly of Selkirk Polyflue Vent Systems 1 This boiler has been listed for use with the Selkirk Polyflue single wall Polypropylene vent system to be provided by the installer 2 Assemble the vent system starting at the boiler a Theventadaptorhasthreedifferen...

Page 56: ...n pipe horizontal terminals Outer edge of exhaust coupling must be 10 or less from the wall surface Figure 7 9 b Remove the gasket from the end of the integral exhaust coupling and insert Selkirk 2PF HVST or 3PFHVST in its place c Add PVC intake per instructions from Section VII F 5 Installation of Vertical Fitting Terminals Terminal Option H a See Figure 7 43 for the proper orientation of twin pi...

Page 57: ...1 Polyflue Pipe Locking Band Installation NOTICE The venting system must be free to expand and contract and supported in accordance with the installation instructions included by the original Polypropylene venting component manufacturer Selkirk Polypropylene pipe sections must be disengaged 1 8 to 1 4 in 3mm to 6mm per joint to allow for thermal expansion Asphyxiation Hazard When using Polyflue fl...

Page 58: ...G Assembly of Selkirk Polyflue Vent Systems continued Figure 7 42 Installation of Selkirk Polyflue UV Resistant Single Wall Horizontal Terminal Figure 7 43 Installation of Selkirk Polyflue UV Resistant Single Wall Vertical Terminal ...

Page 59: ...ing over the male end of the pipe to be joined as shown in Figure 7 44 Push the male end of the next section of pipe into the bell until it bottoms out then back out 1 4 to provide room for thermal expansion Push hook on connecting ring over the bell end of the first section of pipe as shown in Figure 7 44 d Assemble the rest of the vent system per the manufacturer s installation instructions bein...

Page 60: ...rd Screen IASPP02 or IASPP03 in the end of the pipe c A 180 bend or two 90 elbows are installed on the top of the air intake pipe If two 90 elbows are used a rodent screen can be installed between them Figure 7 46 If a 180 bend is used install a rodent screen in the open side of the bend using a ring made of PVC pipe If desired the termination fittings can be attached to the end of the intake pipe...

Page 61: ...ation of Centrotherm InnoFlue UV Stabilized Single Wall Horizontal Terminal Figure 7 46 Installation of Centrotherm InnoFlue UV Stabilized Single Wall Vertical Terminal VII Venting H Assembly of Centrotherm InnoFlue Vent Systems continued ...

Page 62: ... base of the vent Route the smooth section of InnoFlue Flex 3 or Flex Adaptor 2 through a cap in the base of this Tee Use a Centrotherm IAWP2P or IAWP03B wall plate and RTV to seal this penetration Install the Base Support using the Base support bracket as described in the InnoFlue installation manual Connection of the PVC air intake pipe to the side outlet of the tee is made using a cap and a PVC...

Page 63: ...including the chimney cap and adaptor to rigid pipe at base of masonry chimney In addition observe the following requirements a Refer to the appropriate Vent option in table 7 21 for a list of the principle flex components required Rigid vent pipe by the same manufacturer will also be required for the run from the boiler to the base of chimney b Masonry chimneys cannot be used for an air chase Asp...

Page 64: ... wall or roof combustion air terminal The unused chimney flue must be structurally sound and in good repair A chimney is considered UNUSED when it is not being used for any appliance venting If chimney is a multiple flue type where one of the multiple flues is being used for an appliance venting the flexible stainless vent installation is permitted through an adjacent unused flue providing a local...

Page 65: ...5 If the point of condensate disposal is above the trap it will be necessary to use a condensate pump to move the condensate to the drain In such cases select a condensate pump that is appropriate for use with condensing boilers If overflow from this pump would result in property damage select a pump with an overflow switch and use this switch to shut down the boiler Alternatively if heat is a nec...

Page 66: ...II Venting K Removing an Existing Boiler From a Common Chimney Au moment du retrait d une chaudière existante les mesures suivantes doivent être prises pour chaque appareil toujours raccordé au système d evacuation commun et qui fonctionne alors que d autres appareils toujours raccordés au système d évacuation ne fonctionnent pas a Sceller toutes les ouvertures non utilisées du système d évacuatio...

Page 67: ... gas supply system by closing its individual manual shut off valve Locate leaks using an appropriate combustible gas non corrosive leak detector solution VIII Gas Piping Explosion Hazard Failure to properly pipe gas supply to boiler may result in improper operation or leaks of flammable gas Gas supply to boiler and system must be absolutely shut off prior to installing or servicing boiler gas pipi...

Page 68: ...n LP 080 120 14 0 2 5 11 0 Table 8 2 Minimum and Maximum Inlet Pressures VIII Gas Piping continued Figure 8 1 Gas Connection to Boiler MANUAL SHUT OFF VALVE FACTORY SUPPLIED MUST BE INSTALLED WITHIN 6FT OF THE BOILER GROUND JOINT UNION TEE GAS SUPPLY CAP ...

Page 69: ... make up water Inspect the system thoroughly for leaks before placing it in service If the system includes underground piping or other piping in which a leak might go undetected consider isolating the boiler from the system with a heat exchanger Make sure that the expansion tank is properly sized and in good condition If it is not the relief valve may open frequently resulting in regular additions...

Page 70: ...h limit to 200 F Wire the limit per Figure 10 3 in the Wiring section 8 Isolation Valves recommended Isolation valves are useful when the boiler must be drained as they will eliminate having to drain and refill the entire system 9 Strainer recommended Install a Y Strainer or other suitable strainer to prevent any system debris from entering the boiler and fouling the water passages Note that some ...

Page 71: ...nly effective way to provide such protection Section HG614 c of the 2013 ASME boiler and Pressure Vessel Code recognizes the use of a listed flow switch in lieu of a low water cut off on water tube boilers In the event that a local jurisdiction insists upon the installation of a low water cut off with this boiler a Low Water Cut off Kit P N 105591 01 is available that plugs into the low voltage ci...

Page 72: ...e at least 1 In order to keep the flow rates in the system and boiler loops independent of each other provide at least 8 diameters of straight pipe upstream of the first tee and 4 diameters downstream of the second tee Keep the distance between the expansion tank and the first secondary tee as short as practical 2 Boiler Loop Piping All boilers are supplied with a built in circulator which will de...

Page 73: ... Air Vent Header Temperature Sensor When Used Y Strainer Recommended To System System Zone Valves Heating System Circulator Boiler Pump Drain Valve Full Port Isolation Valves Unions Tee Plug Recommended For Future Heat Exchanger Service Relief Valve Close Nipple Locate Header Sensor As Close As Possible To Downstream Tee Hydraulic Separator May Be Substituted For Tees Figure 9 2 Piping Method 1 Ne...

Page 74: ...ize the load placed on the Primary Secondary Header connections 3 Components marked are supplied with the boiler All other components are supplied by the installer 4 3 4 coupling and 3 4 x 4 nipple marked are supplied by the installer and are required to locate the relief valve above the boiler heat exchanger as required by ASME Section IV IX System Piping continued Figure 9 2a Piping Method 1 Nea...

Page 75: ...75 107672 03 5 18 Figure 9 3a Piping Method 1 Near Boiler Piping Heating Plus Indirect Water Heater IX System Piping continued ...

Page 76: ...l Port Isolation Valves Tee Plug Recommended For Future Heat Exchanger Service Relief Valve Close Nipple Locate Header Sensor As Close As Possible To Downstream Tee Hydraulic Separator May Be Substituted For Tees Fill Valve Backflow Preventer Flow Check Full Port Isolation Valves Indirect Circulator Indirect Domestic Water Heater IWH Indirect Supply Indirect Return CAUTION It is the installer s res...

Page 77: ... provide effective connection points for automatic air elimination devices and an expansion tank These separators are available from several sources and may be used in place of the closely spaced tees shown in Figure 9 2 9 3a or 9 3b When a hydraulic separator is used in place of the tees the 60 ft equivalent length limitation still applies Select a hydraulic separator having 1 or larger boiler co...

Page 78: ...78 107672 03 5 18 Figure 9 6 Piping Method 1 Near Boiler Piping Shaded Boiler Loop IX System Piping continued ...

Page 79: ...ce curve for the pump in each boiler model taking into account the pressure drop through the boiler s heat exchanger and internal piping These curves therefore show the flow that can be achieved through the boiler as a function of the pressure drop through the connected piping Calculation of the system pressure drop must be performed by someone having familiarity with pressure drop calculations su...

Page 80: ...ust use Speed HI to achieve the flow requirement shown in Table 9 1 Figure 9 8a Taco Net Circulator Performance Curve Note These curves show the flow that can be achieved through the boiler as a function of the pressure drop through the connected piping IX System Piping continued ...

Page 81: ...ine additions of fresh water Systems which are open to the atmosphere If the boiler is to be used in such a system it must be separated from the oxygenated water being heated with a heat exchanger as shown in Figure 9 10 Consult the heat exchanger manufacturer for proper heat exchanger sizing as well as flow and temperature requirements All components on the oxygenated side of the heat exchanger s...

Page 82: ...additional water temperature limit If necessary install an additional water temperature limit such as a Honeywell L4006 Aquastat Wire as indicated in Figure 10 3 All wiring and grounding must be done in accordance with the authority having jurisdiction or in the absence of such requirements with the National Electrical Code NFPA 70 In Canada all wiring and grounding must be done in accordance with...

Page 83: ...ectly through the indirect water heater Maximum combined current draw for all circulators is 6 3 FLA See Section XII of this manual for information on setting up the pump operation 2 Low Voltage Connections Low voltage field connections on the low voltage PCB are shown in Figure 10 3 and are listed from top to bottom Heat T Stat 24VAC heating thermostat R 24V Hot Heat T Stat 24VAC heating thermost...

Page 84: ...84 107672 03 5 18 Figure 10 2 High Voltage PCB Terminal Connections Figure 10 3 Low Voltage PCB Terminal Connections X Wiring continued ...

Page 85: ...id such noise sources wire the sensor using a 2 conductor UL Type CM AWM Style 2092 shielded cable Connect one end of the shielding on this cable to ground See Section XII of this manual for information on enabling the outdoor reset sensor e Header Sensor When this sensor is installed and enabled the boiler will attempt to maintain the target water temperature in the header rather than in the supp...

Page 86: ...86 107672 03 5 18 Figure 10 5 J3 Field Wiring Figure 10 4 4 20 mA EMS Field Wiring X Wiring continued ...

Page 87: ...rimary Secondary Tee Sensor Clip Header Temperature Sensor Honeywell 32003971 003 U S B C P N 103104 01 Close Nipple Locate Header Sensor As Close As Possible To Downstream Tee Well Should Extend Into Header Flow As Far As Possible Use Extension Only If Necessary Honeywell Immersion Well ...

Page 88: ...88 107672 03 5 18 X Wiring continued Figure 10 7 Internal Ladder Diagram ...

Page 89: ...89 107672 03 5 18 PAGE LEFT INTENTIONALLY BLANK ...

Page 90: ...90 107672 03 5 18 X Wiring continued ...

Page 91: ...91 107672 03 5 18 Figure 10 8 Internal Wiring Connections Diagram X Wiring continued ...

Page 92: ...B 2 STRIP 40b BL SPL BL 1 J8 1 15 GR J4 12 GND 41 YE P8 4 J8 3 16 OR IGNITOR 42 YE P8 5 J7 7 17 P G P10 1 J10 7 43 GY P8 12 SPL GY 1 18 YE P10 2 J10 8 43a GY SPY GY 1 THERM 1 19 P G P10 3 J8 11 43b GY SPL GY 1 J6 1 20 BL P10 7 J3 4 44 Y G P8 11 J6 7 21 OR P10 8 J3 5 45 Y G P8 10 J6 8 22 PI P10 9 SPL P1 1 46 OR P8 9 J3 7 22a PI SPL P1 1 J3 6 47 BL P8 8 J3 8 22b PI SPL P1 1 GT02 2 48 WH P8 7 J3 9 23...

Page 93: ...93 107672 03 5 18 Figure 10 9 TACO SR504 or Equivalent Zone Panel Wiring Connection Diagram X Wiring continued ...

Page 94: ...94 107672 03 5 18 X Wiring continued Figure 10 10 Sage Zone Control Circulator Panel Wiring Connection Diagram ...

Page 95: ...h air Refer to the National Fuel Gas Code for additional information on testing and purging gas lines Completely read understand and follow all instructions in this manual before attempting start up NOTICE Safe lighting and other performance criteria were met with the gas train assembly provided on the boiler when the boiler underwent the test specified in ANSI Z21 13 Burn Hazard The maximum opera...

Page 96: ...blend of glycol for freeze protection and inhibitors to protect the glycol from attacking metallic system components Do not add any more antifreeze than is necessary to protect the system from freeze damage Many of these products require annual testing of the system water to ensure that the inhibitors are still active consult the manufacturer s instructions for maintenance requirements Allowance m...

Page 97: ...er ignition sequence This soft lockout can be reset by interrupting power to the boiler for a few seconds Once a flame has been established for the first time subsequent calls for burner operation should result in a flame on the first try 13 If there is a problem that appears before the first try for ignition or if the boiler fails to light after six tries for ignition the blinking HELP button is ...

Page 98: ...672 03 5 18 Figure 11 3 Burner Flame XI Start Up and Checkout continued Figure 11 2a Home Screen at Power Up No Call for Heat Figure 11 2b Home Screen on Heat Demand Figure 11 2c Home Screen with Active Fault ...

Page 99: ...99 107672 03 5 18 XI Start Up and Checkout continued Figure 11 4 Gas Valve Detail 80B 180B Figure 11 5 Gas Valve Detail 180M ...

Page 100: ...s return arrow to close the keypad h Press SAVE i Press ADJUST j Press MANUAL CONTROL k Press HIGH or LOW as appropriate Do not attempt to operate this boiler on LP gas without converting it using the proper conversion kit Do not attempt to convert this boiler to LP gas without the use of a combustion analyzer Failure to follow the conversion instructions will result in operation of the boiler at ...

Page 101: ...itive Adjust offset no more than 1 8 turn before checking combustion with analyzer Maximum total adjustment 1 turn Failure to follow these instructions could result in death serious injury or substantial property damage Improper gas valve adjustment can result in unreliable operation substantial property damage personal injury or loss of life due to carbon monoxide CO poisoning Observe the followi...

Page 102: ...rform a check of the ignition safety shut off device With the burner firing carefully unplug the orange flame rod wire at the flame rod using a pair of insulated pliers Figure 11 1 The burner should shut off immediately 18 Test any external limits or other controls in accordance with the manufacturer s instructions 19 Refer to the Operation section to set up the control for the system in which the...

Page 103: ...103 107672 03 5 18 Lighting and Operating Instructions XI Start Up and Checkout continued ...

Page 104: ... water temperature as the heating load decreases This boiler is not used for any space heating This boiler is part of a modular or multiple boiler system having a total input of 300 000 BTU hr or greater This boiler is equipped with a combi space heating instantaneous domestic hot water When the boiler is installed with a Sage Zone Control Panel Zone Control into a multiple zone home the Control u...

Page 105: ...e Regulation 1 Priority Demand The Control accepts a call for heat demand from multiple places and responds according to it s Priority When more than 1 demand is present the higher priority demand is used to determine active boiler settings For example Priority Status Screen Display Boiler Responding to 1st Sequencer Control The boiler is connected to the peer to peer network The boiler accepts de...

Page 106: ...l operating XII Operation continued controlandhighlimitfeatures Thecontrolmonitors adualelementtemperaturesensorthatismounted in the supply water manifold and provides UL353 and UL1998 internal safety algorithms If supply water temperature increases above the active setpoint plus diff above default 190 F 87 7 C theboileriscycledoff Ifthetemperatureexceeds 210 F 98 9 C a manual reset hard lockout r...

Page 107: ...trol only controls the system and boiler circulators individual zones are not protected Itisrecommendedthattheboilerbeinstalledinalocation that is not exposed to freezing temperatures D Multiple Boiler Control Sequencer 1 Plug Play Multiple Boiler Control Sequencer When multiple boilers are installed the Control s Sequencer may be used to coordinate and optimize the operation of up to eight 8 boil...

Page 108: ... the initial firing rate is 100 2 or 50 when the third boiler is started the firing rate starts at 200 3 or 66 After the initial start the Sequence Master develops a unison firing rate demand based on it s setpoint and sensed header temperature 10 Innovative Condensing Boiler Control Duringlowloads theSequenceMasterlimitsfiring rates to a Base Load Common Rate to ensure modulating condensing boile...

Page 109: ... Running burner On circulator s On After flame is proven the sequence continues with run stabilization and low fire hold time Once the field adjustable low fire hold time is completed normal boiler operation begins modulation rate depending on temperature and setpoint selections Priority Domestic Hot Water Status Running If the Central Heat call for heat is active and a Domestic Hot Water DHW call...

Page 110: ...eat Domestic Hot Water Sequencer Control peer to peer Demand or Frost Protection Warm Weather Shutdown status is shown Standby is shown when no demand is present Energy Save On Indication Outdoor Air Reset DHW or setback have lowered boiler water setpoint High Efficiency On Indication Return temperature is low enough to allow energy saving flue gas condensation Help Fault correction service contac...

Page 111: ...s screens are the primary boiler monitoring screens The user may simply walk though boiler operation by repeatedly selecting the right or left arrow symbol These screens are accessed by selected the Status button from the Home screen Figure 12 7 Boiler Status Screen Definitions Figure 12 6 Status Screens ...

Page 112: ...s are present when more than one demand is present Pumping is a major part of any hydronic system This screen provides the status of the boiler s demand to connected pumps as well as the status of Frost Protection and pump Exercise functions Bargraph Screen The bargraph screen presents measured values for easy comparison An information screen provides monitoring of Rate Demand To Fan and Fan Speed...

Page 113: ...il Screens Figure 12 8 Detail Screen Overview Zone Control Status press for zone cycles i Zone Panel 1 Demand Cycles KITCHEN 45 BEDROOMS 20 BASEMENT 12 DOMESTIC HOT WATER 26 Active zones are shown by bold underlined numbers Press the zone panel to view zone cycle counts To reset all zone cycle counts press Reset Cycle Counts NOTE Zone cycles are resettable by selecting the reset button located on ...

Page 114: ...ce Of Operation continued 5 Multiple Boiler Sequencer Screens When the Sequence Master is enabled the following screen is available The Sequencer Status screen is selected by pressing Status button from the Home screen when Sequence Master is enabled ...

Page 115: ... and press the return arrow to close the keypad Press the Save button Press the Adjust button to enter Adjustment mode Figure 12 9 Adjust Mode Screens Login to Access Adjustment Mode For Service Contact CONTRACTOR NAME ADDRESS LINE 1 ADDRESS LINE 2 PHONE NUMBER Contractor Adjust Access Level Installer Adjust Password required to Get past here Installer Password 86 Login Warning Improper settings o...

Page 116: ...ensor is not connected to the boiler the sensor is not monitored for faults Wired Outdoor Sensor is installed directly on the boiler terminal Strip 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 Di...

Page 117: ... during the auxiliary heat call for heat If the rated input of the Auxiliary Heat Zones is less than the maximum output of the boiler change the Auxiliary Heat Maximum Expected Heat Rate fan speed setting to limit the boiler output accordingly 100 Minimum to Maximum Heat Rate DHW or BOTH DHW CH The DHW or Both DHW CH parameter is the boiler s maximum modulation when DHW is being serviced simultane...

Page 118: ...mitted 8100 8500 8700 Not Permitted 8000 Minimum Heat rate RPM 1710 1800 1900 1500 Default Light off RPM 4000 4000 4000 4000 Altitude 6001 7800 FT Configuration K2WT 080B 67 N K2WT 100B 67 N K2WT 120B 67 N K2WT 150B 67 N K2WT 180B 67 N K2WT 180M 67 N Maximum Heat Rate RPM 6800 8500 8600 8800 Not Permitted 7800 Minimum Heat rate RPM 1650 1760 1800 1900 1500 Default Light off RPM 4000 4000 4000 4000...

Page 119: ...the maximum heat rate the Control then measures water temperature and fires the boiler only as hard as required for the heat demand Expected Heat Rate Adjustment Screens HeatMatch Software Example call for heat durations for a four zone house Maximum heat rate limits firing rate and prevents the Control from firing to 100 in response to a smaller zone demands Maximum Heat Rate Automatically adjust...

Page 120: ...Demand Never Any Demand Header Sensor Demand CH Off for DHW Boiler Pump run pump for Activates the boiler pump output according to selected function Never Pump is disabled and not shown on status screen Any Demand Pump Runs during any call for heat Header Sensor Demand Pump Runs when boiler is firing and when there is DHW demand Selected when Header Sensor is selected as modulation sensor and boil...

Page 121: ...on This piping arrangement permits the system pump to run or not run when there is a domestic hot water 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 Flow Check Heating Circulators Optional Full Port Isolation Valves Optional Full Port Isolation Valves To System From...

Page 122: ...lators Optional Full Port Isolation Valves Optional Full Port Isolation Valves To System From System Air Separator Air Vent Expansion Tank Header Temperature Sensor When Used Cold Water Line Y Strainer Recommended System Zone Valves Heating System Circulator To System Boiler Pump Drain Valve Unions Full Port Isolation Valves Tee Plug Recommended For Future Heat Exchanger Service Relief Valve Close...

Page 123: ...ic hot water 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 Sequencer Master Boiler 1 Boiler 2 Wiring locations Thermostat X DHW call for heat X System pump X DHW pump X Boiler Pump X X Sequencer Master Parameter Selections ...

Page 124: ... Description Contractor Name User defined Contractor Name Address Line 1 User defined Contractor Address Line 1 Address Line 2 User defined Contractor Address Line 2 Phone User defined Contractor Phone Press button to access the following screen The Manual Speed Control speed screen allows the technician to set firing rate at low or high speed for combustion testing ...

Page 125: ...ture controller Proportion Integral Derivative PID values Higher values cause a larger firing rate change for each degree of temperature change If set too high firing rate overshoots required value increases to high fire causing the temperature to exceed the Diff Above setpoint and cycle the boiler unnecessarily Lower values cause a smaller firing rate change for each degree of temperature change ...

Page 126: ...ng the temperature to exceed the Diff Above setpoint and cycle the boiler unnecessarily Lower values cause a smaller firing rate change for each degree of temperature change If set too low the firing rate response will be sluggish and temperature will wander away from setpoint Disable Disable Enable Auxiliary Priority Over Central Heat This parameter allows the Auxiliary Heat demand to be higher o...

Page 127: ...exceed the Diff Above setpoint and cycle the boiler unnecessarily Lower values cause a smaller firing rate change for each degree of temperature change If set too low the firing rate response will be sluggish and temperature will wander away from setpoint 10 seconds 0 to 300 seconds Low Fire Hold Time Low Fire Hold Time is the number of seconds the control will wait at low fire modulation rate bef...

Page 128: ...0 F 21 1 C 32 F to 100 F 0 C to 37 8 C Central Heat 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 Central Heat Low Boiler Water Temperature The Low Boiler Water Temperature parameter is the...

Page 129: ...o 100 F 40 C to 37 8 C Auxiliary Heat Low Outdoor Temperature The Low Outdoor Temperature parameter is also called Outdoor Design Temperature This parameter is the outdoor temperature used in 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 Auxiliary Heat High Outdoor Temperature The High Outdoor Temperature parameter is the o...

Page 130: ... Setpoint Heating Element Type 180 F to 190 F 82 2 C to 87 8 C Fan Coil 100 F to 140 F 37 8 C to 60 C In Slab Radiant High Mass Radiant 160 F to 190 F 71 1 C to 87 8 C Convection Baseboard Fin Tube Convective 130 F to 160 F 54 4 C to 71 1 C Staple up Radiant Low Mass Radiant 130 F to 160 F 54 4 C to 71 1 C Radiant Baseboard 140 F to 160 F 60 C to 71 1 C Radiators ...

Page 131: ...pond to rapid load increases 70 50 100 Base Load Common Rate To maximize condensing boiler efficiency the firing rate is limited to an adjustable value Boilers are kept at or below this firing rate as long as the boilers can handle the load After last available boiler has started the modulation rate limit is released up to 100 3 1 5 Response Speed This parameter adjusts the Sequence Master tempera...

Page 132: ...and J10 8 is used as the temperature setpoint The following two parameters may be used to adjust the signal range Modbus Modbus is used as the temperature setpoint 130 F 54 4 C 80 F 26 7 C Central Heat Setpoint Central Heat 4 20mAdc Setup 4 mA Water Temperature Sets the Central Heat Temperature Setpoint corresponding to 4mA for signal input on Control Terminals J8 6 and J10 8 Current below 4mA is ...

Page 133: ...tor 2 Long sleeved 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...

Page 134: ...s carbon monoxide nitrogen oxides aldehydes and or other toxic or harmful substances which can cause death or serious injury and which are known to the state of California to cause cancer birth defects and other reproductive harm Always use proper safety clothing respirators and equipment when servicing or working nearby the appliance Failure to follow all instructions in the proper order can caus...

Page 135: ...erify that the gas shutoff shown in Figure 8 1 is closed e Disconnect the flexible gas line at the gas valve flare connection Figure 13 1 f Unplug the electrical connection to the gas valve g Disconnect the air proving switch tube from the gas valve outlet tap h Unplug the power and speed control cables from the blower XIII Service and Maintenance continued Fire Hazard Explosion Hazard Always use ...

Page 136: ...e Gas Line Figure 13 2 Flame Ionization Electrode and Ignition Electrode Location XIII Service and Maintenance continued When disconnecting flexible gas line Place a backup wrench on this nut to prevent damage to the gas valve Flexible Gas Line Connection ...

Page 137: ...on the bottom of the boiler see Figure 2 1 to catch water in the trap as well as the ball and ball support Unscrew the cap being careful not to lose the ball or ball support Flush any debris found in the trap with water do not use other cleaning agents Reassemble the trap as shown in Figure 13 4 q Reinstall the fire door blower gas valve assembly following the above steps in reverse order XIII Ser...

Page 138: ...138 107672 03 5 18 XIII Service and Maintenance continued Figure 13 3 Ignition Electrode Gap Figure 13 4 Condensate Trap Exploded Parts View ...

Page 139: ...er water and the use of boiler water additives u Test the flow switch To do this Start with the boiler in standby Either close a shut off in the boiler loop or unplug the boiler pump at connector L1 see Figure 10 8 Initiate a call for heat and confirm that the boiler shows an Active Fault indicating that the flow switch is open v Follow ALL instructions in Section XI Start up and Checkout to place...

Page 140: ...hing buttons to be directed to the Fault cause B Display Faults Indication Condition Possible Cause Display Completely Dark Fan off LWCO lights off no green power light on Control No 120Vac Power at Boiler Check breaker and wiring between breaker panel and boiler Blown high voltage fuse Replacement Fuse Kit part number 105349 01 Display Completely Dark Fan running No 24Vac Power to Control Loose 1...

Page 141: ...d then Disabled Master s Boiler has been powered down To clear fault restore communication or cycle power Boiler Size Setup Boiler Size Fault WARNING Boiler size setting may not match actual boiler size The Boiler size setting determines min max and light off blower speeds Incorrect boiler size can cause hazardous burner conditions and improper operation that may result in PROPERTY LOSS PHYSICAL I...

Page 142: ...lowing messages appear when the firing rate is limited or reduced to help avoid a lockout or save energy Refer to Hard Lockout section for corrective actions High Stack Temperature Limit High Supply Temperature Limit High Differential Temperature Limit The following messages appear as part of normal start and stop sequences Minimum Modulation normal start stop sequence Low Fire Hold Rate Low fire ...

Page 143: ...et Switch Special Note Before a call for heat the air pressure switch is closed When there is a call for heat with a blocked vent the air pressure switch will open due to excessive pressure of the blower against a blocked flue pipe after the blower starts The control stops the start sequence and stops the blower After the blower stops the pressure switch re closes and the cycle continues The displ...

Page 144: ... for blower speed to match purge and light off setpoint Normal waiting for blower speed to match purge and light off setpoint 27 Undefined Fault Undefined Fault Consult Factory 28 or 53 Air Proving Switch Failed to Close Air Proving Switch Failed to Close The air proving switch has failed to close Check switch check switch connection and wiring Blocked vent blocked inlet blocked or disconnected ai...

Page 145: ...ged or dirty drain line in trap 18 Light off rate proving failed Blower is not running at Light off rate when it should or blower speed signal not being detected by Control Loose connection in 120 VAC blower wiring Loose or miswired blower 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 Cont...

Page 146: ...h your local U S Boiler Wholesale distributor Should you require assistance in locating a U S Boiler distributor in your area or have questions regarding the availability of U S Boiler products or service parts please contact U S Boiler Customer Service at 717 481 8400 or Fax 717 481 8408 ...

Page 147: ... 11C Flame Rod includes flame rod gasket and hardware 105880 01 12A 12B 12C Ignition Electrode includes electrode gasket and hardware 105881 02 13 M6 Serrated Flange Hex Burner Door Nut Obtain locally 14 15 O Ring Repair Kit includes 2 22 mm x 2 mm O rings and 2 connection clips 105888 02 16 17 18 Repair Return Piping Assembly includes return piping assembly 1 circulator flange and circulator flan...

Page 148: ...148 107672 03 5 18 XV Service Parts continued ...

Page 149: ...3 01 107874 01 107875 01 108101 01 27 28 29 Blower Outlet Gasket 106029 01 30 31 34 CSST Gas Line Assembly includes gas line assembly and gasket 106032 01 32 Air Proving Pressure Switch 107862 01 33 Silicone Tubing 105855 01 35 Gas Valve Flange 105831 01 40 Rectifier Module 105829 01 105830 01 44 45 Gas Valve Kit N A 108541 01 41 42 43 44 Blower Kit N A 108540 01 Not Shown 1 2 NPT 90 Street Elbow ...

Page 150: ...80 100 120 150 180 51 52 53 Condensate Trap includes gasket bracket and trap ball 105851 01 54 55 56 57 59 Silicone Tubing includes 3 16 and 3 4 tubing spring clamp and vent fitting 105855 01 58 Sump Pressure Switch 107878 01 XV Service Parts continued ...

Page 151: ...150 180 67 68 69 73 Low Voltage Printed Circuit Board PCB includes Low Voltage PCB and hardware 105853 01 67 70 71 72 73 High Voltage Printed Circuit Board PCB includes Line Voltage PCB insulator gasket and hardware 105852 01 74 8 18 x 1 2 Screw Obtain locally not shown HV LV Fuse 105856 01 ...

Page 152: ...152 107672 03 5 18 XV Service Parts continued ...

Page 153: ... Number Qty 080 100 120 150 180 75 Transformer 106034 01 76 Sage 2 3 Boiler Control 107877 01 77 78 82 97 Control Door Parts 107872 01 79 8 18 x 1 2 Self Tapping Screw Obtain locally 80 Programmable Display GT02L 107864 03 81 8 18 x 1 2 Self Tapping Screw Obtain locally ...

Page 154: ...154 107672 03 5 18 XV Service Parts continued 85 86 91 95 ...

Page 155: ...3 PVC Intake Coupling with Locknut 105848 01 95 Vent Connector includes connector gasket and hardware 107034 01 96 8 18 x 1 2 Screw Obtain locally 98 1 8 x 1 x 3 Hinge Pin Obtain locally 103 105 Jacket Set Unpainted Panels 107904 01 includes 105093 01 and 104680 01 108 Front Cover K2 Decal includes front panel logo plate and K2 decal 108761 01 Not shown 5 16 Flat Washer Obtain locally XV Service P...

Page 156: ...1 NPT x 2 Nipple Obtain locally 119 1 NPT Tee with Side Outlet 107895 01 120 1 x 1 4 NPT Hex Reducing Bushing Obtain locally 121 Temperature Pressure Gauge 105894 01 122 1 x 3 4 NPT Hex Reducing Bushing Obtain locally 123 3 4 NPT X 4 Nipple Obtain locally 124 3 4 NPT 90 Elbow Obtain locally 125 3 4 NPT X 30 Nipple Obtain locally 126 30 psi Relief Valve 81660319 XV Service Parts continued ...

Page 157: ...er 080 100 120 150 180 130 Low Voltage Communication 107876 01 131 High Voltage Harness 105868 01 132 133 135 Trap Flame Trap Ground Circulator Pigtail includes wire harness 105870 01 134 Ignition Cable Harness 105907 01 Not shown LWCO Jumper 105908 01 Not Shown Outdoor Temperature Sensor 102946 01 ...

Page 158: ... installing K2WT 080B or K2WT 180B do not attempt to convert K2WT 080B for use with LP at altitudes above 2000 ft Also do not attempt to install K2WT 180B at altitudes above 2000ft K2WT 180M shall be installed at altitudes ranging from 2001 10100ft Attempts to do so may result in unreliable operation property damage personal injury or loss of life due to carbon monoxide CO poisoning LP Conversions...

Page 159: ...9 0 8 7 9 0 9 0 Low Fire Range and Target values are the same as High Fire above Ensure low fire CO2 reading is less than or equal to high fire CO2 reading Model No Measured O2 Max Co Air Free 2001 6000 ft 6001 7800 ft 7801 10 100 ft Range Target Range Target Range Target K2WT 080B 5 6 6 1 5 6 5 3 5 8 5 3 5 3 5 8 5 3 COAF readings must be less than 200ppm K2WT 100B 4 9 5 4 4 9 5 3 5 8 5 3 5 3 5 8 ...

Page 160: ... 10 100 ft K2WT 080B 0 9 4 0 4 0 K2WT 100B 1 9 2 6 2 7 K2WT 120B 1 2 1 8 2 4 K2WT 150B 2 6 2 9 3 1 K2WT 180B Not Permitted K2WT 180M 0 1 1 9 3 0 NOTE THESE DERATES ARE AT MINIMUM VENT LENGTH Max Vent Length 135 eq Feet 3 inch Intake Vent Pipe Table A2 K2WT Altitudes Derates for Natural Gas Model Counter clockwise Turns From Fully Closed 080 9 3 4 100 9 3 4 120 12 1 4 150 10 180 15 ...

Page 161: ...subdivision can not be met at the time of completion of installation the owner shall have a period of thirty 30 days to comply with the above requirements provided however that during said thirty 30 day period a battery operated carbon monoxide detector with an alarm shall be installed 2 APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in accordance with the above provi...

Page 162: ...ms the following requirements shall be satisfied by the manufacturer 1 The referenced special venting system instructions shall be included with the appliance or equipment installation instructions and 2 The special venting systems shall be Product Approved by the Board and the instructions for that system shall include a parts list and detailed installation instructions e A copy of all installati...

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Page 168: ...168 107672 03 5 18 U S Boiler Company Inc P O Box 3020 Lancaster PA 17604 1 888 432 8887 www usboiler net ...

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