U.S. Boiler Company K2 Installation Instructions Manual Download

Page: 1 / 108

105294-05 - 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).

inSTaLLaTiOn inSTrUCTiOnS

FOr

™

CONDENSING HIGH EFFICIENCY

DIRECT VENT

GAS - FIRED HOT WATER BOILER

Summary of Contents for K2

Page 1: ...gency 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 INSTALLATION INSTRUCTIONS FOR K2 CONDENSING HIGH EFFICIENCY DIREC...

Page 2: ...http 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 installed by a Licensed Plumber or Gas Fitter DANGER Indicates an imminently hazardous situation which if not avoided will result in death serious injury or substantial property damage CAUTION Indicates a p...

Page 3: ...ge 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 damage if the boiler is inoperative Burn Hazard This boiler contains very hot water under high pressure Do not unscrew any pipe fittings nor attempt to disconnect any components of this boiler without posi...

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

Page 5: ...ause extensive property damage Do not leave the heating system unattended during cold weather unless alarms or other safeguards are in place to prevent such damage DO NOT BLOCK AIR 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...

Page 6: ...Systems 50 G Assembly of Selkirk Polyflue Vent Systems 55 H Assembly of Centrotherm InnoFlue Vent Systems 59 I Condensate Trap and Drain 63 J Removing An Existing Boiler From Common Chimney 64 VIII Gas Piping 65 IX System Piping 67 A General System Piping Precaution 67 B Near Boiler Piping Design 68 C Standard Piping Installation Requirements 76 D Piping For Special Situations 78 X Wiring 79 XI St...

Page 7: ...ically 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 A SEE TABLE 2 3 16 5 8 CONNECTION SUPPLY WATER RETURN WATER PRESSURE GAUGE OUTSIDE INSIDE OF WALL CONNECTION OF WALL ACCESS TEMPERATURE PANEL SERVICE DRAIN VALVE 29 1 16 RELIEF VALVE CONDENSATE CONNECTION CONNECTION ...

Page 8: ...essional 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 the authority having jurisdiction...

Page 9: ...wealth of Massachusetts IV Locating the Boiler 1 Observe the minimum clearances shown in Figure 4 1 These clearances apply to combustible construction as well as non combustible walls floors ceilings and doors 2 Note the recommended service clearances in Figure 4 1 These service clearances are recommended but may be reduced to the combustible clearances provided a Access to the front of the boiler...

Page 10: ...10 105294 05 5 15 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 105294 05 5 15 Figure 5 1 Wall Layout Mounting Hole Location V Mounting The Boiler continued ...

Page 13: ...13 105294 05 5 15 Figure 5 2 Boiler Mounting Bracket Installation Boiler Wall Mounting V Mounting The Boiler continued ...

Page 14: ...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 WARNING 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 bo...

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 105294 05 5 15 Figure 7 0c Split Venting VII Venting A Vent System Design continued Figure 7 0a Horizontal Twin Pipe Figure 7 0b Vertical Twin Pipe ...

Page 17: ...ndard radius elbows It is recommended that all field supplied PVC or CPVC elbows be 1 4 Bend Sanitary 90 El or Long Sweep 1 4 Bend type elbows Figure 7 2 In this manual sanitary and long sweep elbows are treated as having the same equivalent length Example A 3 twin pipe horizontal CPVC PVC vent system is planned for a horizontally vented 120MBH model which has the following components in the vent ...

Page 18: ...e boiler Pitch CPVC PVC vent piping 1 4 per foot Pitch Polypropylene vent piping 5 8 per foot Les chaudières de catégories I II et IV doivent présenter des tronçons horizontaux dont la pente montante est d au moins 5 8 po par pied 52 mm m entre la chaudière et l évent VII Venting A Vent System Design continued Table 7 1 Vent Air Intake Fitting Equivalent Length CPVC PVC Fitting Equivalent Length f...

Page 19: ...all 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 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 ...

Page 20: ...20 105294 05 5 15 VII Venting A Vent System Design continued Figure 7 3 Expansion Loops for CPVC PVC Pipe Figure 7 3b Figure 7 3a Figure 7 3c Figure 7 4 Wall Penetration Clearances for PVC Vent Pipe ...

Page 21: ... Polyflue 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 Part VII E of this manual and the Ipex instructions provided with the terminal for installation details Terminal Option C Dive...

Page 22: ...screen ISEP02 or 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 N...

Page 23: ...inal 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 and relief equipment Do not loca...

Page 24: ...ith Low Profile Terminal Vent Options 1 2 Terminal Options B C Figure 7 8 Horizontal CPVC PVC Venting with Concentric Vent Terminal Vent Options 1 2 Terminal Options D E VII Venting B Design Requirements Unique to Horizontal Twin Pipe Venting Systems continued ...

Page 25: ...ntrotherm InnoFlue Horizontal Venting Vent Option 3 8 Terminal Option A Figure 7 10 Duravent 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 ...

Page 26: ...Note Air intake termination not shown refer to Venting Section in K2 Installation Instructions supplied with the boiler 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 27: ...s generally recommended for both terminations Two rodent screens suitable for 3 PVC terminals are supplied with the boiler and are installed as shown in Figure 7 29 If 2 CPVC is used these screens can be cut to fit into the smaller fittings 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 Dura...

Page 28: ...en 3PPS 12B or 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 No...

Page 29: ...K2 180 135ft 135ft 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 i...

Page 30: ... from an outside wall see Part 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 ...

Page 31: ...lex 2 0 ft 2 Centrotherm 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 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 equivalent length ...

Page 32: ...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 33: ...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 34: ... 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 35: ...cated within horizontally within 10ft 3 Horizontal Air Intake Terminal Location Observe the following limitations on the intake terminal location also see Figures 7 22 7 23 or 7 24 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 Reliabl...

Page 36: ...th of 3 DuraVent Poly Pro Flex is 2 0ft From Table 7 1 the equivalent length of the second 90 elbow is 8 7ft The equivalent length of the vent system is therefore 4 8 7 30 x 2 0 72 7ft Since Vent Option 34 shows a max vent length of 135ft the planned vent length of OK Intake Equivalent length First elbow and termination elbow are ignored leaving just the straight pipe Equivalent length of the inta...

Page 37: ...37 105294 05 5 15 THIS PAGE LEFT BLANK INTENTIONALLY ...

Page 38: ...t 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 Intake Flex Termination Components B Vent Chimney Chase Vent Inta...

Page 39: ...Elbow w Screen 90 Elbow w Screen 90 Elbow w Screen 90 Elbow w Screen 90 Elbow w Screen 90 Elbow w Screen 2PPS VFT 2PPS BF 2PPS FLEX 3PPS VFT 3PPS BF 3PPS FLEX 2PF 10UV or 2PF 39UV w Screen 2PF BVSC Note 4 3PF 10UV or 3PF 39UV w Screen 3PF BVSC Note 4 IFBK02 IFBK03 90 Elbow w Screen 90 Elbow w Screen 90 Elbow w Screen 90 Elbow w Screen 90 Elbow w Screen 90 Elbow w Screen Specify size of B vent e g ...

Page 40: ...94 05 5 15 VII Venting D Design Requirements Unique to Split 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 ...

Page 41: ...41 105294 05 5 15 VII Venting D Design Requirements Unique to Split Vent Systems continued Figure 7 24 Split Vent System Flex in Abandoned Masonry Chimney Vent Options 33 38 ...

Page 42: ...4 05 5 15 VII Venting D Design Requirements Unique to Split Vent Systems continued Venting of Other Appliances Or Fireplace into Chase or Adjacent Flues Prohibited Figure 7 25 Masonry Chimney Chase Requirements ...

Page 43: ...e a miter box or other method to cut pipe squarely De burr both the inside and outside of the cut end c Dry fit all vent components before assembly d The vent adaptor has two different inside diameters The larger upper inside diameter accepts 3 CPVC pipe and is used in this application the smaller lower inside diameter accepts 3 nominal PolyPro Polyflue or InnoFlue A locking ring in the adaptor pr...

Page 44: ...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 pi...

Page 45: ...45 105294 05 5 15 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 46: ...nt and intake air pipes through the holes and cement them to the base of the vent termination kit using a primer and cement listed for use with PVC c Fasten the vent base to the wall using the supplied screws and anchors The anchors require the drilling of a 3 16 hole x 1 3 16 deep Locate the holes using the vent base as a template d Screw the vent cap to the vent base using the supplied screws e ...

Page 47: ...5 5 15 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 15 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: ...izontal installations orient so that the side outlet on the Wye is on or above the horizontal plane g For horizontal installations seal the gap between the OD of the outer pipe and the exterior side of the wall with RTV sealant h Cement the rain cap onto the inner pipe If desired the rain cap can be attached to the inner pipe with the supplied stainless steel screw and nut so that it can be later ...

Page 50: ...ng ring in the adaptor prevents the vent pipe from coming out of the adaptor once it is inserted 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 NOTICE Once a vent pipe is inserted into this adaptor it is IMPOSSIBLE to remove it Make sure the correct type of pipe is selected and that it is of the correct ...

Page 51: ... 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 exhaust coupling mus...

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 740 Installation of Duravent PolyPro Concentric Terminal Through Roof ...

Page 55: ... 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 WARNING Asphyxiation Hazard When using PolyPro flex observe the following precautions PolyPro flex may be damaged by handling at low temperatures Do not bend uncoil or attempt to install if it has been stored at a temperature below 42 F without allowing it ...

Page 56: ...oper orientation of twin pipe vertical terminals b Remove the gasket from the end of the integral exhaust coupling and insert Selkirk 2PF HVST or 3PFHVST in its place c A 180 bend or two 90 elbows are installed on the top of the air intake pipe If two 90 elbows are used the rodent screen provided can be installed between them Figure 7 43 If a 180 bend is used install the rodent screen in the open ...

Page 57: ...ference 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...

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 out of the adaptor once it is inserted 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 NOTICE Once a vent pipe is inserted into this adaptor it is IMPOSSIBLE to remove it Make sure the correct type of pipe is selected and that it is of the correct length before inserting it into the vent adaptor b If 2 Inn...

Page 60: ...ing 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 Use plain end UV stabilized Centrotherm 2 pip...

Page 61: ...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 62: ...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 options 20 21 if the B vent has the minimum size shown in Table 7 13b and is fully accessible for sea...

Page 63: ...n disposing of the condensate 1 If the 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 leaki...

Page 64: ...nting J 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 65: ...er 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 Al...

Page 66: ... continued CAUTION Support the weight of the gas line piping independently from the boiler gas connection fitting located on the bottom of the boiler If an additional regulator is used to reduce boiler inlet pressure below 1 2 psig 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 ...

Page 67: ... 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 oxygen If the system is not tight however frequent additions of make up water can expose the heat exchanger to oxygen on a continuous basis In addition fr...

Page 68: ...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 tee Keep the distance betw...

Page 69: ...69 105294 05 5 15 Figure 9 2 Piping Method 1 Near Boiler Piping Heating Only IX System Piping continued ...

Page 70: ... 105294 05 5 15 Figure 9 2a Piping Method 1 Near Boiler Piping with K2 FastPipe Primary Secondary Header Heating Only PRIMARY SECONDARY HEADER INSTALLATION 106259 01 Sizes 080 120 106259 02 Sizes 150 180 ...

Page 71: ...71 105294 05 5 15 Figure 9 3a Piping Method 1 Near Boiler Piping Heating Plus Indirect Water Heater IX System Piping continued ...

Page 72: ...72 105294 05 5 15 IX System Piping continued Figure 9 3b Piping Method 2 Near Boiler Piping Heating Plus Indirect Water Heater ...

Page 73: ...n 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 connections that is designed f...

Page 74: ...74 105294 05 5 15 Figure 9 6 Piping Method 1 Near Boiler Piping Shaded Boiler Loop IX System Piping continued ...

Page 75: ...ne advantage to this method is its installation simplicity It may make sense to use this method when the boiler is to be installed with a new single zone system having a low pressure drop Figure 9 8 shows the performance 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...

Page 76: ...ust use Speed HI to achieve the flow requirement shown in Table 9 1 Figure 9 8a Taco Net Circulator Performance Curve IX System Piping continued Note These curves show the flow that can be achieved through the boiler as a function of the pressure drop through the connected piping ...

Page 77: ...th no other changes in the system the old expansion tank can generally be reused If the expansion tank must be replaced consult the expansion tank manufacturer s literature for proper sizing 5 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 f...

Page 78: ...r cut off with this boiler a Low Water Cut off Kit P N 105591 01 is available that plugs into the low voltage circuit board refer to Section X and LWCO Instruction Sheet for LWCO location and electrical connection 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 probe type low water cut off is used be certa...

Page 79: ... 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 valves to prevent chilled water from entering the ...

Page 80: ...adlock once power is turned off WARNING 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 the Canadian Electrical Code Part 1 CSA C22 1 latest edition Failure to properly wire electrical connections to the boile...

Page 81: ...nt 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 thermostat W Energized or Call for Heat Heat T Stat 24VAC heating ther...

Page 82: ...82 105294 05 5 15 Figure 10 2 High Voltage PCB Terminal Connections Figure 10 3 Low Voltage PCB Terminal Connections X Wiring continued ...

Page 83: ...luorescent lighting Wire the sensor to the boiler using 22 gauge or larger wire As with the sensor itself the sensor wiring should be routed away from sources of electrical noise Where it is impossible to avoid 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 i...

Page 84: ...84 105294 05 5 15 Figure 10 4 Proper Installation of Header Sensor X Wiring continued ...

Page 85: ... C Igniter Flame Rod P8 9 P8 8 Factory Wire Harness PCB Trace Components Field wiring Connector Screw Terminal P3 3 L3 1 J4 4 J4 2 J4 6 J4 3 J4 5 J4 7 Combustion Fan 120V Conn 1 3 2 F1 6 3A Slow Blow P3 10 P3 11 P3 7 P3 12 J8 10 J8 4 J8 9 J8 8 J8 11 J8 5 J10 7 J10 8 P10 1 P10 3 Header Sensor Outdoor Sensor J6 7 J6 8 P8 11 P8 10 ECOM D R C RJ45 ECOM Flue Gas Sensor 1 DC 2 Tach 4 PWM 5 DC J2 3 Fan P...

Page 86: ...86 105294 05 5 15 X Wiring continued ...

Page 87: ...87 105294 05 5 15 Figure 10 6 Internal Wiring Connections Diagram X Wiring continued ...

Page 88: ...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 89: ...89 105294 05 5 15 Figure 10 8 TACO SR504 or Equivalent Zone Panel Wiring Connection Diagram X Wiring continued ...

Page 90: ...90 105294 05 5 15 X Wiring continued Figure 10 9 Sage Zone Control Circulator Panel Wiring Connection Diagram ...

Page 91: ...ent and remove 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 pr...

Page 92: ...1 inhibited Propylene Glycol available from Alent plc Consumer Products Division 4100 6th Avenue Altoona PA 972 547 6002 fernox_usa alent com U S Boiler Part 101146 01 is for a 5 gallon bucket Refer to the antifreeze manufacturer s instructions for required dosage In general these products are a blend of glycol for freeze protection and inhibitors to protect the glycol from attacking metallic syst...

Page 93: ...y 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 four tries for ignition the blinking red screen with HELP highlighted on the Home screen Figure 11 2c To...

Page 94: ...294 05 5 15 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 95: ...d result in property damage personal injury or loss of life due to carbon monoxide CO poisoning WARNING Asphyxiation Hazard The outlet pressure for the gas valve has been factory set and requires no field adjustment This setting is satisfactory for both natural gas and propane Attempting to adjust the outlet pressure may result in damage to the gas valve and cause property damage personal injury o...

Page 96: ...ng 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 Manual to set up the control for the system in which the boiler is installed Some common set up tasks include Setting the CH and DHW temperature set points as shipped both setpoints are set to 180...

Page 97: ...97 105294 05 5 15 Lighting and Operating Instructions XI Start Up and Checkout continued ...

Page 98: ...uel mixture without a proper combustion analyzer could result in unreliable boiler operation personal injury or death due to carbon monoxide poisoning WARNING This conversion kit shall be installed by a qualified service agency in accordance with the manufacturer s instructions and all applicable codes and requirements of the authority having jurisdiction If the information in these instructions i...

Page 99: ...om Fully Closed K2 080 3 3 4 K2 100 3 K2 120 4 K2 150 2 3 4 K2 180 6 1 2 FIGURE A 1a GAS VALVE DETAIL 80MBH THRU 120MBH FIGURE A 1b GAS VALVE DETAIL 150MBH 180MBH Table A 2 Starting Number of Throttle Turns for Conversion to LP Gas Appendix A continued ...

Page 100: ...er both on and off 9 A sheet of yellow labels is provided in the envelope with this manual for boilers converted from natural to LP gas Select the model from this sheet of labels and apply them as follows Apply the Rating Plate Label adjacent to the rating plate Apply the Gas Valve Label to a conspicuous area on the gas valve Apply the Boiler Conversion Label to a conspicuous surface on or adjacen...

Page 101: ...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 Press 5 digit display to open a keypad Enter the password 86 and press the return arrow to close keypad Press Save button 8 Press Adjust button to ente...

Page 102: ...tion check CO2 and CO Air Free and ensure it is within the limits outlined in Table B1 of this Supplement Air Free Carbon Monoxide in Flue Gas must be less than 200 ppm during all operation If CO Air Free and CO2 is within these limits move to Step 6 and check fan speed at high fire operation only 5 If CO2 is outside the window outlined in Table B1 of this Supplement adjust throttle screw such tha...

Page 103: ...20 NG 8 8 9 3 8 8 9 3 8 8 9 3 0 0 0 6 LP 9 9 10 2 9 9 10 2 9 5 9 8 0 0 5 0 6 K2 150 NG 8 6 9 3 8 6 9 3 8 6 9 3 0 0 4 1 0 LP 9 8 10 3 9 8 10 3 9 8 10 1 0 3 1 2 1 4 K2 180 NG 8 5 9 1 8 5 9 1 8 5 9 1 2 0 1 9 1 7 LP 9 9 10 3 9 9 10 2 No application 2 5 2 4 No application NOTE THESE DE RATES ARE AT MINIMUM VENT LENGTH Max Vent Length 135 eq feet 3 inch Intake Vent Pipe Table B1 K2 Altitude Adjustments ...

Page 104: ...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 105: ...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 106: ...106 105294 05 5 15 ...

Page 107: ...107 105294 05 5 15 ...

Page 108: ...108 105294 05 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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U.S. Boiler Company K2, Installation Instructions Manual

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