Burnham K2WTC Installation, Operating And Service Instructions Download Page 6

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107774-01 - 9/17

Table of Contents

I. Product Description

II. Specifications

III. Before Installing

IV. Locating The Boiler

V. Mounting The Boiler

VI. Air For Ventilation

VII. Venting

A. Vent System Design

B. Design Requirements Unique to Horizontal Twin Pipe Venting Systems 22
C. Design Requirements Unique to Vertical Venting Systems

D. Design Requirements Unique to Split Vent Systems

E. Assembly of CPVC/PVC Vent Systems

F. Assembly of DuraVent PolyPro Vent Systems

G. Assembly of Selkirk Polyflue Vent Systems

H. Assembly of Centrotherm InnoFlue Vent Systems

I. Assembly of Stainless Steel Vent Systems

J. Condensate Trap and Drain

K. Removing An Existing Boiler From Common Chimney

VIII. Gas Piping

IX. System Piping

A. General System Piping Precaution

B. Standard Piping Installation Requirements

C. Near Boiler Piping Design

D. Piping For Special Situations

X. Domestic Hot Water Piping

XI. Wiring

XII. Start-Up and Checkout

XIII. Operation

101

XIV. Service and Maintenance

124

XV. Troubleshooting

131

XVI. Repair Parts

140

Appendix A: Instructions for High Altitude Installation Above 2,000 ft.

153

Appendix B: Special Requirements For Side-Wall Vented Appliances

In The Commonwealth of Massachusetts

156

Summary of Contents for K2WTC

Page 1: ...ation consult a qualified installer service agency or the gas supplier This boiler requires a special venting system Read these instructions carefully before installing 9700609 As an ENERGY STAR Partner U S Boiler Company has determined that the K2WTC Series meets the ENERGY STAR guidelines for energy efficiency established by the United States Environmental Protection Agency EPA INSTALLATION OPER...

Page 2: ...roperty damage WARNING Indicates a potentially hazardous situation which if not avoided could result in death serious injury or substantial property damage NOTICE Indicates special instructions on installation operation or maintenance which are important but not related to personal injury hazards DANGER Explosion Hazard DO NOT store or use gasoline or other flammable vapors or liquids in the vicin...

Page 3: ...o 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 prevent scald injuries Do not rely on the pressure and temperature gauges to determine the temperature and pressure of the boiler This boiler contains components which become very hot when ...

Page 4: ...R FLOW into or around the boiler Insufficient air may cause the boiler to produce carbon monoxide or start a fire KEEP FLAMMABLE LIQUIDS AWAY from the boiler including paint solvents and gasoline The boiler may ignite the vapors from the liquids causing explosion or fire KEEP CHILDREN AND PETS away from hot surfaces of the boiler boiler piping vent piping and vent terminals CARBON MONOXIDE CO is a...

Page 5: ...t 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 peak hot water load whichever is larger A grossly oversized boiler will cycle ex...

Page 6: ...Systems 56 H Assembly of Centrotherm InnoFlue Vent Systems 60 I Assembly of Stainless Steel Vent Systems 64 J Condensate Trap and Drain 66 K Removing An Existing Boiler From Common Chimney 67 VIII Gas Piping 68 IX System Piping 70 A General System Piping Precaution 70 B Standard Piping Installation Requirements 71 C Near Boiler Piping Design 73 D Piping For Special Situations 79 X Domestic Hot Wat...

Page 7: ... vented vertically or horizontally 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 A SEE TABLE 2 4 INSIDE OF WALL OUTSIDE OF WALL 30 ACCESS CONNECTION DOOR RELIEF CONDENSATE TRAP CLEANOUT INSIDE CABINET PRESSURE GAUGE AIR INTAKE CONNECTION CONNECTION CONDENSATE VAL...

Page 8: ... NPT Male Boiler Water Content Gal Net Weight lbs Supply Return Hot Cold Gas 135 15 1 3 4 1 2 0 53 109 150 19 1 3 4 1 2 0 79 126 180 19 1 3 4 1 2 0 79 126 1 Safe reliable operation of this boiler depends 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 jurisdi...

Page 9: ...ruction Non concentric vent exhaust Air intake piping 0 Hot water piping 4 The relief valve must be installed in the location shown in Figure 2 1 and must be in the same space as the boiler 5 The boiler should be located so as to minimize the length of the vent system 6 The combustion air piping must terminate where outdoor air is available for combustion and away from areas that will contaminate ...

Page 10: ...10 107774 01 9 17 Figure 4 1 Minimum Clearances To Combustible Construction IV Locating the Boiler continued ...

Page 11: ...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 12: ...12 107774 01 9 17 Figure 5 1 Wall Layout Mounting Hole Location V Mounting The Boiler continued ...

Page 13: ...13 107774 01 9 17 Figure 5 2 Boiler Mounting Bracket Installation Boiler Wall Mounting V Mounting The Boiler continued ...

Page 14: ...intained with all doors to the room closed no ventilation openings are required for this boiler If the above service clearances cannot be maintained provide two openings into the room one near the floor and one near the ceiling The top edge of the upper opening must be within 12 of the ceiling and the bottom edge of the lower opening within 12 of the floor Each of these openings must have a free a...

Page 15: ...nly 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 WARNING Asphyxiation Hazard Failure to vent this boiler in accordance with these instructions co...

Page 16: ...16 107774 01 9 17 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 17: ...he first 90 elbow If more elbows are desired the maximum allowable vent length must be reduced by the amount shown in Table 7 1 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 treated as havi...

Page 18: ...nt adaptor b Fit a 3 CPVC coupling on length of pipe Glue coupling to pipe using a field supplied cement and primer that is listed for use with materials being joined CPVC and or PVC c Insert attenuator in length of pipe Ensure attenuator tube is pointing down and sits inside 3 CPVC coupling d Install remaining venting as described in this manual If using one of the polypropylene or stainless stee...

Page 19: ...n combustible walls see 9 Air Intake 0 Concentric Portion of Concentric Terminals 0 7 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 VII Venting A Vent System Design continued Table 7 1B Vent Air Intake Fitting Equivalen...

Page 20: ... can expand towards the terminal When a straight run of pipe exceeds 20ft and must be restrained at both ends an offset or expansion loop must be provided Figures 7 3a 7 3b When a straight horizontal run of pipe exceeds 20ft and is restrained at one end with an elbow at the other avoid putting a hanger or guide less than Y inches from the elbow in the adjoining straight section Figure 7 3c Thermal...

Page 21: ...21 107774 01 9 17 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 22: ...ption B Ipex Low Profile Terminal Acceptable for Vent Option 1 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 Low Profile Terminal Acceptable f...

Page 23: ...l Option A Fittings Vent Coupling w screen Note 3 3PPS 12B or 3PPS 36B w screen 3PF 10UV or 3PF 39UV w screen ISEP03 or ISEP0339 w screen Intake Elbow w screen Note 3 Elbow w screen Elbow w screen Elbow w screen Terminal Option B Ipex Low Profile Ipex 196985 Not Permitted Terminal Option C DiversiTech HVENT HVENT 3 Not Permitted Terminal Option D Ipex FGV Concentric Ipex 196006 Not Permitted Termi...

Page 24: ...rs The bottom of the vent terminal must be at least 3 feet above any forced air inlet located within 10 feet USA Only A clearance of at least 4 feet horizontally must be maintained between the vent terminal and gas meters electric meters regulators and relief equipment Do not install vent terminal over this equipment In Canada refer to B149 1 Installation Code for clearance to meters regulators an...

Page 25: ...irements 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 PER ...

Page 26: ... Option 2 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 TRIM COLLAR SELKIRK POLYFLUE OR CENTROTHERM INNOFLUE VENT PIPE BUILDING EXTERIOR 4 PITCH INTAKE AWAY FROM BOILER IF POSSIBLE BOILER ROOM PVC AIR INTAKE PIPE BUILDING EXTERIOR PITCH VENT PIPE 5 8 PER FOOT TOWARDS BOILER 3 DURAVE...

Page 27: ...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 28: ... of PolyPro Polyflue or InnoFlue exposed to the outdoors must be UV resistant Use of rodent screens not supplied is generally recommended for both terminations These can be fabricated from 2 x 2 1 2 mesh stainless steel screen Rodent screens and are installed as shown in Figure 7 29 Rodent screens bird guards for PolyPro InnoFlue and Polyflue are as follows Size Vent System Rodent Screen Bird Guar...

Page 29: ...en Intake 180 Elbow w Screen 180 Elbow w Screen 180 Elbow w Screen 180 Elbow w Screen Terminal Option I Ipex FGV Concentric Ipex 196006 Note 3 Not Permitted Terminal Option J DiversiTech CVENT Concentric CVENT 3 Not Permitted Terminal Option K DuraVent Vertical Concentric Not Permitted 3PPS VK Not Permitted Notes 1 Max vent lengths shown also apply to the intake For example Vent Option 1 may have ...

Page 30: ...ize of B vent e g 3PPS BV6 is for use with 6 B vent Specify length in feet Specify Flex length and B vent diameter e g IFBK032506 includes 25ft of flex and used with 6 B vent Note 1 Max vent lengths shown also apply to the intake Flex vent reduces the maximum allowable vent length See equivalent lengths for flex vent shown in Table 7 14 and sizing example on next page VII Venting C Design Requirem...

Page 31: ...n 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 pipe is c...

Page 32: ...alent Length ft Flex Vent 1 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 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 equivalent length ...

Page 33: ...al CPVC PVC Venting Vent Option 5 Terminal Option H Figure 7 16 Vertical CPVC PVC Venting with IPEX Concentric Vent Terminal Vent Option 5 Terminal Option I J VII Venting C Design Requirements Unique to Vertical Venting Systems continued ...

Page 34: ...Centrotherm InnoFlue Vertical Single Wall PP Venting Vent Options 6 8 Terminal Option H Figure 7 18 Duravent PolyPro Vertical Venting with Concentric Terminal Vent Option 6 Terminal Option K VII Venting C Design Requirements Unique to Vertical Venting Systems continued ...

Page 35: ...VII Venting C Design Requirements Unique to Vertical Venting Systems continued Figure 7 19 Duravent PolyPro B Vent Air Chase System Vent Option 9 Figure 7 20 Centrotherm InnoFlue B Vent Air Chase System Vent Option 10 3 ...

Page 36: ...e 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 the intake terminal is subjected to winds in excess of 40 mph Air i...

Page 37: ...lexible vent installation is not permitted through any of the adjacent flues Asphyxiation Hazard Flexible stainless steel vent must be installed only in an UNUSED chimney flue A chimney flue 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 in...

Page 38: ...upling w Screen 3PPS 12B or 3PPS 36B w Screen 3PF 10UV or 3PF 39UV w Screen ISEP03 or ISEP0339 w Screen Not Permitted Intake 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 Permitted 3PPS FK 3PPS FLEX 3PF FLEX KIT 3PF FLEX Intake 90 Elbow w Screen 90 Elbow w Screen Flex Termination Components B Vent Chimney C...

Page 39: ...0 135ft 135ft 180 135ft 135ft Rigid Vent Terminals Vent Not Permitted Intake Flex Termination Components Masonry Chimney Chase Vent IFCK03 2SVSCKIT03 2SVFLXCN03 Intake 90 Elbow w Screen 90 Elbow w Screen Flex Termination Components B Vent Chimney Chase Vent IFBK03 2SVFLXR03 Intake 90 Elbow w Screen 90 Elbow w Screen Specify length in feet Specify Flex length and B vent diameter e g IFBK032506 incl...

Page 40: ...plit Vent Systems continued Figure 7 22 Split Rigid Vent System Vent Options 11 14 Figure 7 23 Split Vent System Flex in B Vent Chase Vent Options 15 17 PVC AIR INTAKE PIPE FIRE STOP LISTED FOR USE WITH VENT SYSTEM PITCH 1 4 PER FT TOWARDS TRAP PVC AIR INTAKE PIPE ...

Page 41: ...doned Masonry Chimney Vent Options 15 17 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 42: ...ique to Split Vent Systems continued Figure 7 24b Flexible PP Masonry Chimney Chase Requirements Venting of Other Appliances Or Fireplace into Chase or Adjacent Flues Prohibited WITH CROWN 45 MAX BOILER CHIMNEY AND FOUNDATION ARE STRUCTURALLY SOUND BOILER ...

Page 43: ...XIBLE LINER EXTERIOR WALL PLATE BOILER FEMALE FLEX ADAPTER MALE FLEX ADAPTER RIGID ELBOW FOR SS FLEX PIPE ALTERNATE VENT PIPING RIGID TEE WITH CONDENSATE DRAIN CAP 12 MIN 10 OR LESS NORMAL SNOW LINE ABOVE GROUND LEVEL PVC ELBOW WITH RODENT SCREEN PVC AIR INTAKE PIPE OUTSIDE WALL RAIN CAP Figure 7 25a Split Vent Systems SS Flex in Abandoned Masonry Chimney Vent Option 18 Figure 7 25b Flexible SS Ma...

Page 44: ...CPVC piping before 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 ...

Page 45: ... 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 and a tap hole in the end of the vent in...

Page 46: ...46 107774 01 9 17 Figure 7 29 Installation of Standard Vertical Terminals Figure 7 28 Installation of Standard Horizontal Terminals VII Venting E Assembly of CPVC PVC Vent Systems continued ...

Page 47: ...o this terminal If the vent system is too short to permit this use the IPEX FGV CPVC terminal a For horizontal installations at the planned location cut a round hole in the exterior wall 1 2 larger than the C dimension indicated on Figure 7 32 for the size terminal being used See Section VII B of this manual for permitted terminal locations b For vertical installations cut a hole in the roof large...

Page 48: ...1 9 17 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 49: ...9 17 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 50: ...50 107774 01 9 17 Figure 7 34 Installation of IPEX and DiversiTech Concentric Terminal Through Roof VII Venting E Assembly of CPVC PVC Vent Systems continued ...

Page 51: ...the boiler a The vent adaptor has three different inside diameters The middle inside diameter accepts 3 nominal PolyPro Figure 7 27 A locking band clamp in the adaptor prevents the vent pipe from coming out of the adaptor once it is installed and tightened Lubricate the upper gasket in the vent adaptor with soapy water and insert the first piece of 3 PolyPro into the adaptor until it bottoms out T...

Page 52: ...dance with the installation instructions included by the original Polypropylene venting component manufacturer M G DuraVent Polypropylene pipe sections must be disengaged 1 4 to 5 8 in 6 mm to 16 mm per joint to allow for thermal expansion 4 Installation of Horizontal Fitting Terminals Terminal Option A a See Figure 7 36 for proper orientation of twin pipe horizontal terminals Outer edge of exhaus...

Page 53: ...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 54: ...tion 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 is on or above the ho...

Page 55: ...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 56: ...t adaptor in the base of this Tee as described in the DuraVent PolyPro Flex instructions Connection of the PVC air intake pipe to the side outlet of the tee is made using a cap and a PVC socket x male thread adaptor Cut a clearance hole in the cap for the male threads Secure the adaptor to the cap using a 3 electrical conduit lock nut Seal all joints with RTV G Assembly of Selkirk Polyflue Vent Sy...

Page 57: ...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 43 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 pipes with field supplied stainless steel screws so that they can be later r...

Page 58: ...rence the Selkirk Polyflue instruction manual Not all vent configurations shown in the Selkirk vent manual are approved for use with this boiler Refer to Selkirk Polyflue Instructions for assembly of all flex components including the chimney cap and the adaptor to rigid Polyflue at the base of the masonry or B vent chimney In addition observe the following requirements a Refer to the appropriate V...

Page 59: ...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 60: ...side diameters The middle inside diameter accepts 3 nominal InnoFlue Figure 7 27 A locking band clamp in the adaptor prevents the vent pipe from coming out of the adaptor once it is installed and tightened Lubricate the upper gasket in the vent adaptor with water and insert the first piece of 3 InnoFlue into the adaptor until it bottoms out Tighten locking band clamp to secure vent pipe b Assemble...

Page 61: ...s included by the original Polypropylene venting component manufacturer Centrotherm Polypropylene pipe sections must be disengaged 1 4 in 6mm per joint to allow for thermal expansion 4 Installation of Horizontal Fitting Terminals Terminal Option A a See Figure 7 45 for proper orientation of twin pipe horizontal terminals Outer edge of end pipe must be 10 or less from the wall surface Figure 7 5 b ...

Page 62: ...stallation 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 ...

Page 63: ...efer to the appropriate Vent option in Tables 7 13b or 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 c B vent chimneys can only be used for an air chase Vent option 10 if the B vent has the minimum size shown in Table 7 13b...

Page 64: ...here is a 0 minimum clearance between the air intake piping and all types of construction d To the extent possible pitch horizontal air intake piping towards the outside WARNING Asphyxiation Hazard Vent systems made by Duravent rely on gaskets for proper sealing When these vents systems are used take the following precautions Make sure that gasket is in position and undamaged in the female end of ...

Page 65: ...xible stainless steel pipe manufacturer installation instructions and boiler installation Operating and Service Instructions the more restrictive instructions shall govern WARNING Asphyxiation Hazard Flexible stainless steel vent must be installed only in an UNUSED chimney flue A chimney flue in considered UNUSED when it is not being used for any appliance venting If chimney is a multiple flue typ...

Page 66: ...he corrugated condensate drain line must be extended construct the extension from PVC or CPVC pipe Insert the hose provided with the boiler into the end of the extension as shown in Figure 7 47 2 Condensate is slightly acidic Do not use metallic pipe or fittings in the condensate drain line Do not route the drain line through areas that could be damaged by leaking condensate 3 Some jurisdictions m...

Page 67: ...nting K Removing an Existing Boiler From a Common Chimney continued WARNING Never common vent this boiler with other appliances 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 S...

Page 68: ...iler from the gas supply system by closing its individual manual shut off valve Locate leaks using approved combustible gas non corrosive leak detector solution VIII Gas Piping WARNING Explosion Hazard Failure to properly pipe gas supply to boiler may result in improper operation or leaks of flammable gas Gassupplytoboilerandsystemmustbeabsolutelyshutoffpriortoinstallingorservicingboilergaspiping ...

Page 69: ...g 3 4 kPa it must be at least 6 to 10 ft upstream of the boiler It is very important that the gas line is properly purged by the gas supplier or utility company Figure 8 1 Gas Connection to Boiler NOTICE Install 1 2 ground joint union nut side down as shown in Figure 8 1 Failure to do so will make it difficult or impossible to remove burner for servicing Model Max Natural LP Min Natural Min LP 135...

Page 70: ... assist in system cleaning See Section XII Start up and Check out for recommended cleaners 2 Make sure that the system is tight This is the single most important guideline Tap water contains dissolved oxygen which causes corrosion In a tight system this oxygen comes out of solution and is quickly removed from the system through the automatic air vent The system then remains essentially free of oxy...

Page 71: ...a tank for an anti freeze system should be at least 1 2 times greater in size 4 Fill Valve required Either a manual or automatic fill valve may be used but a manual valve is preferred because it eliminates unmonitored additions of make up water to the system The ideal location for the fill valve is at the expansion tank If using antifreeze with automatic fill valve it is recommended to install a w...

Page 72: ...witch 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 refer to Part XI and the low water cut off manufacturer s instructions for proper wiring Install the low water cut off in the supply piping at the point prescribed the local jurisdiction generally at a point above the boiler If a pr...

Page 73: ...nd piping to obtain the design flow rate through the heating system as you would on any other heating system All piping between the expansion tank and secondary connection tees must be 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 te...

Page 74: ...74 107774 01 9 17 IX System Piping continued Figure 9 2 Piping Method 1 Near Boiler Piping Heating Only IX System Piping continued ...

Page 75: ...n tank These separators are available from several sources and may be used in place of the closely spaced tees shown in Figure 9 2 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 connections that is designed for the boiler flow rates shown in Table 9 1 Table 9 3 Equivalent Lengths fo...

Page 76: ...76 107774 01 9 17 Figure 9 5 Piping Method 1 Near Boiler Piping Shaded Boiler Loop IX System Piping continued IX System Piping continued ...

Page 77: ... through the entire system must be known This method is generally not recommended because it is often very difficult to accurately calculate the pressure drop through the system In replacement installations it may be impossible to get an accurate measurement of the amount of piping and number of fittings in the system In addition if the system is zoned the system flow may drop well below the minim...

Page 78: ... Curve Taco 0011 0 5 10 15 20 25 30 35 40 0 2 4 6 8 10 12 14 Flow GPM Available Head ft 0 5 10 15 20 25 30 35 0 2 4 6 8 10 Flow GPM Available Head ft 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 79: ...Figure 9 8 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 such as the pump and expansion tank must be designed for use in oxygenated water 2 Piping with a Chiller If the boiler is used in conjunction with a chiller pipe the boiler and chiller in parallel Use isolation ...

Page 80: ...tion using piping the same size as the discharge connection on the valve 4 Hose Bib Valves Recommended These valves permit the DHW plate heat exchanger be periodically back flushed to remove sediment 5 Globe or Ball Valve Recommended Used to aid in back flushing the heat exchanger and to isolate the DHW piping if it must be serviced In addition the upstream valve may be used to limit the DHW flow ...

Page 81: ...81 107774 01 9 17 X Domestic Hot Water Piping continued Figure 10 1 Domestic Hot Water Piping ...

Page 82: ...controls NOTICE This boiler is equipped with a listed high water temperature limit function This limit provides boiler shutdown in the event the boiler water temperature exceeds the set point of the limit control Certain Local Codes require an additional water temperature limit If necessary install an additional water temperature limit such as a Honeywell L4006 Aquastat Wire as indicated in Figure...

Page 83: ...e two terminals must be removed Failure to remove this jumper will render the external safety devices ineffective b Outdoor Sensor Use only the Tasseron TSA00AA outdoor sensor supplied with the boiler When this sensor is con nected and enabled the boiler will adjust the target supply water temperature downwards as the outdoor air temperature increases This sensor should be located on the outside o...

Page 84: ...84 107774 01 9 17 Figure 11 2 Line Voltage Field Connections Figure 11 3 Low Voltage PCB Terminal Connections XI Wiring continued ...

Page 85: ...CO be installed with this boiler There are two ways to wire a LWCO into this boiler A 120V LWCO may be wired to break 120V power to the boiler Figure 11 4a A 24V LWCO may be wired so that its contacts are wired to the external limit connections on the boiler When this is done a separate transformer must be supplied by the installer to power the LWCO s sensing circuit This transformer must be compl...

Page 86: ...86 107774 01 9 17 Figure 11 4b 24 Volt LWCO Field Wiring XI Wiring continued Figure 11 4a 120 Volt LWCO Field Wiring Figure 11 5 J3 Field Wiring ...

Page 87: ...4 J8 9 J8 8 J8 11 J8 5 J10 7 J10 8 Outdoor Temp J6 7 J6 8 Flue Gas Sensor 1 DC 2 Tach 4 PWM 5 DC J2 3 Fan PWM J2 4 DC J2 1 Tach J2 2 DC Combustion Fan DC Conn T1 8 T1 7 Internal non replaceable 2 amp J6 1 L3 2 L2 1 L2 3 Thermal Fuse Ground screw in boiler J box Air Proving Switch L Wire Nut N P1 1 P1 2 P1 5 P5 1 P5 7 P3 5 P3 4 P2 3 P2 2 P2 6 P3 9 P3 1 P3 12 P3 10 P3 3 P3 11 P4 5 P4 4 P4 1 P4 11 P4...

Page 88: ...88 107774 01 9 17 XI Wiring continued XI Wiring continued ...

Page 89: ...89 107774 01 9 17 Figure 11 7 Internal Wiring Connections Diagram XI Wiring continued ...

Page 90: ...2 P3 12 SPL GY 1 14a YE J8 2 SPL Y 1 24a GY SPL GY 1 FLOW 1 14b YE SPL Y 1 P3 2 P3 2 GAS 2 24b GY SPL GY 1 SPS 15 GR J4 12 P3 3 P3 3 IGN GND 25 GY SPS THERM 2 16 RD J5 2 P3 4 P3 4 GAS 1 26 BL J4 3 P5 7 P5 7 ZV 1 17 BL L3 1 SPL BL 1 27 RD J4 5 P5 1 P5 1 BP 1 17a BL SPL BL 1 J8 1 28 YE J8 3 P2 4 17b BL SPL BL 1 P2 1 29 YE J10 7 P2 2 17c BL SPL BL 1 P3 5 P3 5 APS 30 RD J10 8 P2 3 17d BL SPL BL 1 P5 2...

Page 91: ...91 107774 01 9 17 Figure 11 9 TACO SR504 or Equivalent Zone Panel Wiring Connection Diagram XI Wiring continued ...

Page 92: ...92 107774 01 9 17 Figure 11 10 Sage Zone Control Circulator Panel Wiring Connection Diagram XI Wiring continued ...

Page 93: ...move hose 7 Check all gas piping for leaks and purge piping sections that are filled with air Refer to the National Fuel Gas Code for additional information on testing and purging gas lines 8 Confirm vent system is complete and free of obstructions before attempting to fire boiler 9 Inspect all wiring for loose uninsulated or miswired connections 10 If the boiler is to be converted to propane conv...

Page 94: ... are a 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 Allo...

Page 95: ...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 highlighted on the Home screen Figure 12 2c Touching this HELP button will take the user to the Diagnostic...

Page 96: ...on Heat Demand Figure 12 2c Home Screen with Active Fault 180 F Energy Save On High Efficiency On Help Adjust Standby Status Detail i kbtu hr 0 Boiler Combi 180 F Energy Save On High Efficiency On Help Adjust Central Heat Status Detail i kbtu hr 80 Boiler Combi 180 F Energy Save On High Efficiency On Help Adjust Standby Status Detail i kbtu hr 0 Boiler Combi ...

Page 97: ...esulting in property damage Before attempting to operate this boiler at altitudes above 2000 ft follow instructions shown in Appendix A of this manual 16 Perform a combustion test Boilers are equipped with a screw cap in the vent adapter Be sure to replace this cap when combustion testing is complete Check CO2 or O2 and CO at both high and low fire Ensure the door panel is sealed before combustion...

Page 98: ...justments are needed make them as follows a With burner at high fire adjust gas valve throttle Fig 12 4 as needed to obtain CO2 or O2 setting shown in Table 12 5A To reduce the CO2 increase the O2 turn throttle clockwise To increase the CO2 reduce the O2 turn throttle counter clockwise Make adjustments in increments of 1 8 to 1 4 turns and allow the boiler at least a minute to respond before makin...

Page 99: ...ctly installed and are operating properly when the installation is complete Model Counter clockwise Turns From Fully Closed 135 12 1 4 150 10 180 15 Table 12 5B Starting Number of Throttle Turns for Natural Gas XII Start Up and Checkout continued NOTICE In some cases such as when the gas valve is replaced the throttle may be far enough out of adjustment that it is not possible to fire the boiler w...

Page 100: ...100 107774 01 9 17 Lighting and Operating Instructions XII Start Up and Checkout continued ...

Page 101: ... boiler 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 4 HeatMatchTM Software When the boiler is installed with a Sage Zone Control Panel Zone Control into a multiple zone home the Control uses a patent pending HeatMatch Software to improve hom...

Page 102: ...on and there is no Central Heat or DHW demand NOTE May be user selected to be higher priority than Central Heat 4th Frost Protection Frost Protection is active and there is no other call for heat 5th Warm Weather Shutdown WWSD WWSD is active and the boiler will not respond to central heat demands DHW demand is not blocked by WWSD 6th Standby There is no demand detected Table 13 1 Order of Priority...

Page 103: ...es faster than the degrees Fahrenheit per second limit a soft lockout is activated XIII Operation continued 2 High Differential Temperature Limit The Control monitors the temperature difference betweenthereturnandsupplysensors Ifthisdifference exceeds 52 F 29 C the control begins to reduce the maximum blower speed If temperature difference exceeds 62 F 34 C a forced boiler recycle results Theunitw...

Page 104: ...e Started Start Temperatures Stop Temperatures Boiler Pump Outside Air 0 F 18 C Supply Water 45 F 7 2 C Outside Air 4 F 16 C Supply Water 50 F 10 C Boiler Supply Water 38 F 3 3 C Supply Water 50 F 10 C D Multiple Boiler Control Sequencer This boiler may be used as a slave in a multiple boiler system where the other boilers employ the same control Consult factory for additional information on doing...

Page 105: ...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 for heat received the DHW dem...

Page 106: ...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 107: ... F Rate Zone Control Status press for zone cycles Panel 1 1 2 3 4 Panel 2 1 2 3 4 i Status 50 Rate Stack 180 F 180 F Return Supply 180 F i Heat Demand Central Heat ON Auxiliary Heat Off Domestic Hot Water Off Frost Protection Off System Circ ON 98 Boiler Circ ON 23 DHW Valve CH 0 Circulator Status Cycles i Flame Signal 9 43 uA Boiler Cycles 10 Run Time Hours 2 Burner Status i NOTE Only visible if ...

Page 108: ...s This screen provides the status of the boilers five 5 possible heat demands When demand is off the Control has not detected the call for heat This screen allows the user to determine which demands are present when more than one demand is present Cycles and Hours Boiler cycles and hours are used to monitor the boilers overall compatibility to the heating load Excessive cycling compared to run tim...

Page 109: ...re only shown when the Sequence Master is enabled 4 Detail Screens Figure 13 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 ...

Page 110: ...he return arrow to close the keypad Press the Save button Press the Adjust button to enter Adjustment mode Figure 13 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 or service cr...

Page 111: ...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 112: ...change the Central Heat Maximum Expected Heat Rate fan speed setting to limit the boiler output accordingly 100 Minimum to Maximum Heat Rate Domestic Hot Water DHW Maximum Heat Rate This parameter defines the highest modulation rate the Control will go to during a Domestic Hot Water call for heat Adjustment generally not recommended 100 Minimum to Maximum Heat Rate Auxiliary Maximum Heat Rate This...

Page 113: ...ferent from NG K2WTC 135B 26 P Maximum Firing Rate CH DHW RPM 8500 Minimum Firing Rate RPM 1800 Default Light off Rate RPM 4000 Altitude 6001 7800ft Model K2WTC 135B 68 N K2WTC 150B 68 Not Permitted on Either Fuel Maximum Firing Rate CH DHW RPM 8600 8800 Minimum Firing Rate RPM 1800 1900 Default Light off Rate RPM 4000 4000 LP Model if different from NG K2WTC 135B 68 P Maximum Firing Rate CH DHW R...

Page 114: ...creens 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 adjusted by the Control based on the size and number of zones calling for heat Actual Heat Rate Boiler is free to modulate based on temperature from minimum to maximum h...

Page 115: ...t according to selected function Central Heat No Priority Pump Runs during central heat auxiliary heat and frost protection call for heat Pump does not start for a DHW call for heat but will run during Domestic Hot Water Priority if there is also a call for space heat Central heat Optional Pump Runs during central heat auxiliary heat and frost Priority protection call for heat Pump does not start ...

Page 116: ...d 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 117: ...ow degrees below the setpoint 3 1 to 5 Response Speed This parameter adjusts the Central Heat temperature 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...

Page 118: ...below the setpoint 3 1 to 5 Response Speed This parameter adjusts the Auxiliary Heat temperature 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 unnecess...

Page 119: ...domestic hot water demand will have priority for the duration of this Priority time At the end of that time the boiler will respond to the call for space heat and no domestic hot water will be available until there is an interruption in one of the two demands During the priority time itself any interruption in the DHW or space heat demand will also reset the clock both demands need to be present o...

Page 120: ...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 121: ...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 122: ...t 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 123: ... Modbus Address when a Energy Management System is connected Normal Use Boiler First Normal Use Boiler Last Slave Selection Order Use Boiler First places the Slave in the lead permanently Normal firing order follows boiler number 1 2 3 order Use Boiler Last places the slave last in the firing order Factory Setting Range Choices Parameter and Description Local Local 4 20mA Central Heat Modulation S...

Page 124: ... approved respirator 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 crystalli...

Page 125: ...y metals 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 c...

Page 126: ...ched securely d Verify that the gas shutoff shown in Figure 8 1 is closed e Disconnect the union under the boiler Figure 8 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 NOTICE Warranty does not cover boiler damage or malfunction if the following steps are not p...

Page 127: ...127 107774 01 9 17 Figure 14 1 Flame Ionization Electrode and Ignition Electrode Location XIV Service and Maintenance continued ...

Page 128: ...ondensate cleanout cap 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 14 3 q Reinstall the fire door blower gas valve assembly following the above steps in...

Page 129: ...Parts View CONDENSATE HOSE FROM HEAT EXCHANGER CONDENSATE TRAP VENT TUBING CONDENSATE TRAP CABINET COMPONENTS OMITTED FOR CLARITY I BALL FLOAT 0 I FLOAT SUPPORT GASKET I FLOAT SUPPORT 1 mf O RING FOR CLEANOUT CAP I CLEANOUT CAP E J CLEANOUT CAP NUT CONDENSATE TRAP VENT PRESSURE SWITCH TUBING CORRUGATED CONDENSATE TUBING FROM TRAP ...

Page 130: ... on boiler water and the use of boiler water additives u Test the boiler 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 BP1 see Figure 11 6 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 XII Start up and ...

Page 131: ...s not provide space heat when it is responding to a DHW demand Priority time can be shortened but this may cause a lack of hot water at fixtures during long DHW draws No hot water at fixtures Boiler not responding to call for DHW Status and Priority show Standby Boiler is not seeing DHW demand Verify that draw rate though boiler itself is at least 0 5GPM a higher draw may be needed at the fixture ...

Page 132: ...en light is connected to internal power supply The power supply is repeatedly starting and stopping not normal making the light flash The microprocessors are not running Try disconnecting all terminals except 24VAC to power the Control The green light should be steady If it is not then the control is defective If steady start plugging in all the connectors while watching the green light When fault...

Page 133: ...nd 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 ...

Page 134: ...ted 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 hold rate is a normal start up rate hold used to he...

Page 135: ...sure 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 displays shows the cause of trip for only the time the pressure...

Page 136: ...r 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 air switch t...

Page 137: ...lower 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 Control Loose connection in 120 VAC blower wiring Loose or miswired blower speed harness Defective blower 20 Invalid Safety Para...

Page 138: ...6 30 8056 104 40 5324 122 50 3599 140 60 2483 158 70 1748 176 80 1252 194 90 912 212 100 674 230 110 506 248 120 384 Table 15 3b Outdoor Air Temperature Sensor Temperature versus Resistance Outdoor Temperature Ohms of Resistance F C 20 28 9 106926 10 23 3 80485 0 17 8 61246 10 12 2 47092 20 6 7 36519 30 1 1 28558 40 4 4 22537 50 10 0 17926 60 15 6 14356 70 21 1 11578 76 24 4 10210 78 25 6 9795 80 ...

Page 139: ...6028 50 10 0 22804 55 12 8 20301 60 15 6 17906 65 18 3 15948 68 20 0 14773 70 21 1 14157 75 23 9 12616 77 25 0 12000 80 26 7 11268 85 29 4 10048 86 30 0 9804 90 32 2 9026 95 35 0 8054 100 37 8 7275 104 40 0 6652 105 40 6 6526 110 43 3 5899 115 46 1 5319 120 48 9 4810 122 50 0 4607 125 51 7 4359 130 54 4 3945 135 57 2 3591 140 60 0 3252 XV Troubleshooting continued ...

Page 140: ...t Number 135 150 180 1 Fixing Clamp Bracket Contact U S Boiler Company Provide boiler serial number 2 Holding Clamp 3 M4 x 7 Fixing Clamp Screw 4 10 32 x 1 2 Thread Cutting Screw 5 Bare Heat Exchanger 6 Flue Outlet Gasket 105882 01 7 Flue Temperature Sensor 105883 01 8 Rear Target Wall Insulation 105651 01 9 Cold Burner Door Black Outer Gasket 106030 01 10 Cold Burner Door Assembly 105877 01 10587...

Page 141: ...141 107774 01 9 17 XVI Repair Parts continued ...

Page 142: ...e Sensor 105910 01 21 17 17A 22 Piping Block Kit 108209 01 108210 01 23 27 Supply Pipe Repair Kit includes supply piping assembly and locknut 108212 01 24 Supply Temperature Sensor 105911 01 25 T P Gauge 108215 01 26 26A Boiler Supply Flow Switch O Ring 105892 01 28 30 psi Relief Valve 81660319 29 Supply U Bend 108213 01 108214 01 13 29A 33 35 47 Plate HX includes mounting bracket hardware and fib...

Page 143: ... 9 17 XVI Repair Parts continued Key No Description Part Number 135 150 180 40 43 27 46 47 DHW Fitting Set 108197 01 41 41A DHW Flow Switch 108155 01 42 44 DHW CSST Set 108196 01 45 DHW Temperature Sensor 108154 01 ...

Page 144: ...144 107774 01 9 17 XVI Repair Parts continued ...

Page 145: ... Gas Conversion Kit excludes M models 107874 01 107875 01 48 49 50 Blower Outlet Gasket 106029 01 51 52 Gas Line Seal includes gas line escutcheon plate gasket and hardware 107898 01 53 Air Proving Pressure Switch 107861 01 107862 01 54 67 68 69 70 71 73 Tubing Repair Kit 108218 01 55 1 2 NPT x 7 Steel Nipple Obtain locally 56 Gas Valve Flange 107901 01 61 Rectifier Module excludes M models 105829...

Page 146: ...scription Part Number 135 150 180 62 63 64 Condensate Trap includes gasket bracket and trap ball 105851 01 65 Ball for Condensate Trap 105850 01 66 Trap Harness Kit 107159 01 54 67 68 69 70 71 73 Tubing Repair Kit 108218 01 72 Sump Pressure Switch 107878 01 ...

Page 147: ...147 107774 01 9 17 XVI Repair Parts continued ...

Page 148: ...r Gasket Replacement Kit 108188 01 78 Transformer 106034 01 81 Ignition Cable 107152 01 82 Boiler Control 2 3 107877 01 84 85 86 87 88 89 120 121 J Box Replacement Kit 108207 01 90 91 Low Voltage Printed Circuit Board includes low voltage PCB and hardware 107141 01 74 75 76 77 100A Control Box includes gaskets and hardware 108194 01 ...

Page 149: ...149 107774 01 9 17 XVI Repair Parts continued ...

Page 150: ...s gaskets 108216 01 108217 01 99 K2WTC Replacement Door 108202 01 101 102 Intake Repair Kit 105848 01 103 104 Vent Connector includes connector gasket and hardware 107034 01 106 107 108 109 110 Front Door Hardware 108200 01 111 111A 126 Display Assembly 108198 01 114 Wall Mounting Bracket 102989 01 115 5 16 X 2 Lag Screw Washer Obtain locally ...

Page 151: ...151 107774 01 9 17 XVI Repair Parts continued 120 121 122 123 124 125 126 127 ...

Page 152: ...1 122 Internal DC Harness 108206 01 123 Internal AC Harness 108205 01 124 Circ Zone Valve Harness 3 req d per boiler 108192 01 125 Control Box Harness 108195 01 126 Display Harness 108199 01 127 Combi Wire Harness 108193 01 Not Shown Outdoor Temperature Sensor 102946 01 XVI Repair Parts continued ...

Page 153: ...mpleted first Select the correct K2WTC boiler size altitude and fuel range using the touch screen display as follows 1 Check boiler s rating label for actual boiler size 2 Confirm installation altitude 3 Power up the boiler The display will show the Home screen 4 Press Adjust button on the Home screen 5 Press Adjust button on the Adjust Mode screen 6 Press Login button to access Password screen 7 ...

Page 154: ...mitted LP 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 Fuel Measured O2 Max Co Air Free 2001 6000 ft 6001 7800 ft 7801 10 100 ft Range Target Range Target Range Target K2WTC 135B NG 4 7 5 3 4 7 4 7 5 3 4 7 5 3 5 8 5 3 COAF readings must be less than 200ppm LP 6 2 6 6 6 2 5 6 6 0 5 6 Not Permitte...

Page 155: ...180 15 14 Appendix A continued Model No Fuel Approximate Derate per 1000 ft 2001 6000 ft 6001 7800 ft 7801 10 100 ft K2WTC 135B NG 1 2 1 8 2 4 LP 1 7 3 3 Not Permitted K2WTC 150B NG 2 6 2 9 3 1 LP 3 2 3 0 3 3 K2WTC 180B NG Not Permitted LP NOTE THESE DERATES ARE AT MINIMUM VENT LENGTH Max Vent Length 135 eq Feet 3 inch Intake Vent Pipe Table A2 K2WTC Altitudes Derates ...

Page 156: ...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 provisions shall comply with NFPA 720 and be ANSI UL 2034 listed and IAS certified 3 SIGNAGE A ...

Page 157: ...irements 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 installation instructions for a...

Page 158: ...158 107774 01 9 17 SERVICE RECORD DATE SERVICE PERFORMED ...

Page 159: ...159 107774 01 9 17 SERVICE RECORD DATE SERVICE PERFORMED ...

Page 160: ...160 107774 01 9 17 U S Boiler Company Inc P O Box 3020 Lancaster PA 17604 1 888 432 8887 www usboiler net ...

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