U.S. Boiler Company K2 Operating Instructions Manual Download Page 1

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105337-03 - 5/15

Price - $5.00

Warning:

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

injury, or loss of life. For assistance or additional information, consult a 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 K2™ Series meets the EnErgY

STar

guidelines for energy efficiency established by the United States Environmental Protection Agency (EPA).

OPEraTing inSTrUCTiOnS

FOr

™

CONDENSING HIGH EFFICIENCY

DIRECT VENT

GAS - FIRED HOT WATER BOILER

Summary of Contents for K2

Page 1: ...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 th...

Page 2: ...ttp license reg state ma us pubLic pl_products pb_pre_form asp for the latest Approval Code or ask your local Sales Representative The Commonwealth of Massachusetts requires this product to be install...

Page 3: ...f 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...

Page 4: ...4 105337 03 5 15 Table of Contents I Operation 5 II Troubleshooting 33...

Page 5: ...r can be configured to start a lag boiler after operating at 50 modulation rate for longer than an adjustable time The boilers are modulated in unison parallel modulation rate to ensure even heat dist...

Page 6: ...or is automatically adjusted as a thermostat s sleep or Away Modes or Outdoor Air Reset 5 Outdoor Air Reset Ifanoutdoortemperaturesensorisconnectedtotheboiler and Outdoor Reset is enabled the Central...

Page 7: ...he boiler will shut down and an open limit indication and error code are provided If the limit installed is a manual reset type it will need to be reset before the boiler will operate 5 Boiler Mounted...

Page 8: ...6 Multiple Demands TheSequenceMasterrespondstoCentralHeat Auxiliary Heat DHW and frost protection demands similar to the standaloneboiler Forexample whenselectedandDHW priorityisactive thesequencemast...

Page 9: ...ce 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 setpoin...

Page 10: ...e symbol returns to the display to previous menu or screen Repeatedly pressing the Close symbol will always return the display to the Home screen Arrow Symbol The Arrow symbol links together all scree...

Page 11: ...boiler protection logic the 6 symbol blinks and becomes a screen link Rate The rate value is equal to the actual kbtu hr input divided by the boiler rated input Priority The selected Priority is shown...

Page 12: ...mance For example studying a differential temperature trend may indicate pump speed settings need to be changed Trend Screens NOTE Firing Rate Trend shows fan demand and feedback Burner Status Screen...

Page 13: ...ld zone number with a solid underscore Press the zone control button to view individual zone Zone Panel 1 typical for 2 through 4 Zone panel screens show individual zone status cycle counts and indivi...

Page 14: ...Domestic Hot Water Frost Protection or Warm Weather Shutdown The Sequencer Status screen is selected by pressing Status button from the Home screen when Sequence Master is enabled The Networked Boiler...

Page 15: ...n on the Home screen Press the Adjust button on the Adjust Mode screen or Press Service Contact for service provider contact information Press Login button to access password screen Press 5 digit disp...

Page 16: ...trol s measurement matching the reference reading Not Connected Connected Not Connected Zone Control Status Connected When the Zone Control is connected adjustable settings are automatically shown und...

Page 17: ...Expected Heat Rate This parameter defines the highest modulation rate the Control will go to during a Domestic Hot Water call for heat If the rated input of the indirect water heater is less than the...

Page 18: ...565 7620 6984 7200 7150 Minimum Light off RPM 3500 3500 3500 3500 3500 Maximum Light off rate RPM 4000 4000 4000 4000 4000 Altitude 4501 7800 Ft Parameter K2 80 57 K2 100 57 K2 120 57 K2 150 57 K2 180...

Page 19: ...pected Heat Rate Adjustment Screens HeatMatch Software Figure 6 Four Zone House with Zone Control Connected Figure 7 Expected Heat Rate Adjustment with Zone Control Connected Example call for heat dur...

Page 20: ...Demand Any Demand Header Sensor Demand Boiler Pump run pump for Activates the boiler pump output according to selected function Any Demand Pump Runs during any call for heat Header Sensor Demand Pump...

Page 21: ...djustable Parameters continued Single boiler Indirect Water Heater IWH Piped to Primary Optional Domestic Hot Water Priority Sequencer Master Boiler 1 Boiler 2 Wiring locations Thermostat X DHW call f...

Page 22: ...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 I Operation F Changing Adjustable Parameters continued Example Pum...

Page 23: ...reen without Saving Clear Entire Field Backspace Save Field and Exit Save Press box to input contractor information Contractor Name i Bill Smith 1 7 6 5 4 3 2 A ES C D C B 8 CL R 7 BS 8 Enter Contract...

Page 24: ...is 180 F the maximum Diff Above is 20 F Further if the setpoint is 190 F the maximum Diff Above is 10 F 5 F 2 8 C 2 F to 25 F 1 1 C to 14 C Central Heat Diff Below The boiler starts when the water tem...

Page 25: ...at 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 require...

Page 26: ...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 rat...

Page 27: ...the coldest outdoor temperature 70 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...

Page 28: ...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...

Page 29: ...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...

Page 30: ...nd 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 l...

Page 31: ...tral Heat 3 User defined Zone Control 2 Zone 3 Central Heat 4 User defined Zone Control 2 Zone 4 Central Heat 1 User defined Zone Control 3 Zone 1 Central Heat 2 User defined Zone Control 3 Zone 2 Cen...

Page 32: ...10 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 Setp...

Page 33: ...Help button flashes and the home screen turns a red color Continue to select flashing buttons to be directed to the Fault cause B Display Faults Indication Condition Possible Cause Display Completely...

Page 34: ...itch settings have changed Set Master Slave switch to Master Set Zone Control switch ZC1 to ON Cycle power Zone Panel Electronics Failure A Zone Panel Duplicate Zone The Control has detected duplicate...

Page 35: ...Limit The following 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...

Page 36: ...only the time the pressure switch is open 3 Boiler Safety Limit Open Boiler Safety Limit or External Limit wired to terminals J5 1 OPEN Jumper for External Limit wired to terminals 11 and 12 or devic...

Page 37: ...s purged of air and that appropriate valves are open Sensor wiring reversed Supply or return sensor defective 16 Supply temp has risen too quickly Supply water temperature has risen too quickly See po...

Page 38: ...not being detected by Sage2 2 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...

Page 39: ...39 105337 03 5 15...

Page 40: ...40 105337 03 5 15 U S Boiler Company Inc P O Box 3020 Lancaster PA 17604 1 888 432 8887 www usboiler net...

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