U.S. Boiler Company K2 Operating Instructions Manual Download Page 6

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105337-03 - 5/15

i.  Operation

B.  Supply Water Temperature 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, when Domestic Hot Water (DHW) has priority 

the setpoint, “Diff Above”, “Diff Below” and pump 

settings are taken from DHW selections. Active “Priority” 

is displayed on the “Boiler Status” screen.

Priority Status Screen 

Display

Boiler Responding to:

1st

Sequencer 

Control

The boiler is connected to the peer-

to-peer  network.  The  boiler  accepts 

demand from the Sequencer Master.

2nd

Domestic Hot 

Water

DHW call for heat is on and selected 

as the priority demand. DHW is always 

higher priority than Central Heat. It also 

has higher priority than the Sequencer 

Control when DHW priority is “enabled” 

and “Boiler Piped” IWH is selected.

3rd

Central Heat

Central  Heat  call  for  heat  is  on  and 

there  is  no  DHW  demand  or  DHW 

priority time has expired.

4th

Auxiliary Heat Auxiliary Heat call for heat is on and 

there  is  no  Central  Heat  or  DHW 

demand.  (NOTE:      May  be  user 

selected  to  be  higher  priority  than 

Central Heat.)

5th

Frost 

Protection

Frost Protection is active and there is 

no other call for heat. Frost protection 

will be a higher priority than Sequencer 

Control if the Sequence Master has no 

active call for heat. 

6th

Warm 

Weather 

Shutdown 

(WWSD)

WWSD  is  active  and  the  boiler  will 

not respond to central heat demands. 

DHW  demand  is  not  blocked  by 

WWSD. 

7th

Standby

There is no demand detected.

Table 1:  Order of Priority

2.  Setpoint Purpose

  The Control starts and stops the boiler and modulates 

the boiler input from minimum (MBH) to maximum 

(MBH) in order to heat water up to the active setpoint.  

The setpoint is determined by the priority (Central Heat 

or Domestic Hot Water) and as described in the following 

paragraphs.  

3.  Central Heat Setpoint

  Upon a Central Heat call for heat the setpoint is either the 

user entered Central Heat Setpoint, or is automatically 

adjusted by a thermostat’s “Sleep” or “Away” modes 

and/or Outdoor Air Reset or, an Energy Management 

System (EMS) supplied 4-20mAdc setpoint. 

4.  Auxiliary Heat Setpoint

 

Auxiliary Heat is a second heating demand that may 

be used to serve either lower temperature radiation or 

warmer heat demands such as fan coils.  Upon an Auxiliary 

Heat call for heat the setpoint is either the user entered 

Auxiliary Heat Setpoint or is automatically adjusted as 

a thermostat’s “sleep” or, Away Modes or, Outdoor Air 
Reset

.

5.  Outdoor Air Reset

  If an outdoor temperature sensor is connected to the boiler 

and Outdoor Reset is enabled, the Central Heat setpoint 

will automatically adjust downwards as the outdoor 

temperature increases.  When the water temperature is 

properly matched to heating needs there is minimal chance 

of room air temperature overshoot.  Excessive heat is 

not sent to the room heating elements by “overheated” 

(supply water temperature maintained too high a setting) 

water.  Reset control saves energy by reducing room 

over heating, reducing boiler temperature & increasing 

combustion efficiency and, reducing standby losses as a 

boiler and system piping cool down to ambient following 

room over heating.

6.  Boost Time

  When the Central Heat Setpoint is decreased by Outdoor 

Air Reset settings the Boost function can be enabled to 

increase the setpoint in the event that central heat demand 

is not satisfied for longer than the Boost Time minutes.  The 

Boost feature increases the operating temperature setpoint 

by 10°F (5.6°C) every 20 minutes (field adjustable) the 

central heat demand is not satisfied. This process will 

continue until heat demand is satisfied (indoor air is at 

desired temperature). Once the heat demand is satisfied, 

the operating setpoint reverts to the value determined by 

the Outdoor Air Reset settings. If Boost Time is zero, 

then the boost function is not used.

7.  Domestic Hot Water (DHW) Setpoint

  Upon a DHW call for heat the setpoint is either the  user 

entered DHW setpoint or the Thermostat’s “Sleep” or 

“Away” DHW setpoint. The optimal value of this setpoint 

is established based on the requirements of the indirect 

water heater.

8.  Domestic Hot Water Priority (DHWP)

  When domestic hot water priority is selected and there is 

a DHW call for heat, the system pump will be turned off 

(when “System Pump Run Pump for” parameter is set for 

“Central Heat Optional Priority”) and the DHW pump will 

be turned on. Additionally, if outdoor reset is active, the 

active setpoint is adjusted to the DHW Setpoint. Priority 

protection is provided to ensure central heat supply in the 

case of excessively long DHW call for heat.

9. “Setback” Setpoints

  User adjustable Thermostat “Sleep” or “Away” Setback 

Setpoints are provided for Central Heat, Auxiliary Heat  

and DHW demands. The Setback setpoint is used when 

the EnviraCOM thermostat is in “leave” or “sleep” modes.  

When setback is “on” the thermostat setback setpoint shifts 

the reset curve to save energy while the home is in reduced 

room temperature mode.  The Honeywell VisionPro IAQ 

(part number TH9421C1004) is a “setback” EnviraCOM 

enabled thermostat. 

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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