U.S. Boiler Company K2FT-085 Installation, Operating And Service Instructions Download

Page: 1 / 176

106375-01 - 4/16

Price - $5.00

9700609

As an ENERGY STAR

Partner, U.S. Boiler Company has determined that the K2FT™ Series meets the ENERGY

STAR

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

INSTALLATION, OPERATING AND

SERVICE INSTRUCTIONS FOR

K2FT

™

CONDENSING HIGH EFFICIENCY

DIRECT VENT

GAS - FIRED HOT WATER BOILER

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.

Space Heating Models:

• K2FT-085

• K2FT-110

• K2FT-155

• K2FT-205

• K2FT-270

Combi Domestic Hot Water

and Space Heating Model:

• K2FTC-155

Summary of Contents for K2FT-085

Page 1: ...G HIGH EFFICIENCY DIRECT VENT GAS FIRED HOT WATER BOILER 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 Space Heating M...

Page 2: ...bstantial property damage CAUTION Indicates a potentially hazardous situation which if not avoided may result in moderate or minor injury or property 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...

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: ...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: ...EAD THIS ENTIRE MANUAL before attempting installation start up or service Improper installation adjustment alteration service or maintenance may cause serious property damage personal injury or death DO NOT DISCONNECT PIPE FITTINGS on the boiler or in the heating system without first verifying that the system is cool and free of pressure and that your clothing will protect you from a release of ho...

Page 6: ...entrotherm InnoFlue Vent Systems 59 I Condensate Trap and Drain 62 J Removing An Existing Boiler From Common Chimney 64 VIII Gas Piping 65 IX System Piping 67 A General System Piping Precaution 67 B Standard Piping Installation Requirements 68 C Near Boiler Piping Design 70 D Piping For Special Situations 81 X Wiring 82 XI Start Up and Checkout 92 XII Operation 99 XIII Service and Maintenance 128 ...

Page 7: ...ace heating and or indirect domestic hot water DHW heating Model K2FTC 155 provides economical tankless domestic hot water DHW heating in addition to central space heating I Product Description II Specifications Figure 2 1 General Configuration CONTROL ACCESS PANEL TEMPERATURE PRESSURE GAUGE GAS CONNECTION CONDENSATE TRAP CLEANOUT CONDENSATE CONNECTION AIR INTAKE CONNECTION VENT CONNECTION RELIEF ...

Page 8: ...5 80 K2FT 270 270 54 251 218 95 4 6 1 1 2 145 80 The Net AHRI Water Ratings shown are based on a piping and pickup allowance of 1 15 The manufacturer should be consulted before selecting a boiler for installations having unusual piping and pickup requirements such as intermittent system operation extensive piping systems etc Figure 2 2 Boiler Internal Component Locations II Specifications continue...

Page 9: ...ust pipe lengths will not be exceeded in the planned installation Also verify that the vent terminal can be located in accordance with Section VII Venting 3 Make sure that the boiler is correctly sized For heating systems employing convection radiation baseboard or radiators use an industry accepted sizing method such as the I B R Guide RHH published by the Air Conditioning Heating and Refrigerati...

Page 10: ...se 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 is provided through a door b Access is provided to the condensate trap located beneath the boiler Note...

Page 11: ...EW SERVICE ACCESS PANEL PROVIDE ACCESS TO THIS AREA FOR INSPECTION AND CLEANOUT OF CONDENSATE TRAP RIGHT SIDE CLEARANCE MAY BE REDUCED TO 1 2 HOWEVER RELIEF VALVE MUST REMAIN IN SAME SPACE AS BOILER 1 2 Figure 4 1 Minimum Clearances To Combustible Construction ...

Page 12: ...e Figure 5 1 to locate 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 ...

Page 13: ...13 106375 01 4 16 Figure 5 1 Wall Layout Mounting Hole Location V Mounting The Boiler continued ...

Page 14: ...14 106375 01 4 16 Figure 5 2 Boiler Mounting Bracket Installation Boiler Wall Mounting V Mounting The Boiler continued ...

Page 15: ...ith 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 th...

Page 16: ...tems WARNING Asphyxiation Hazard Failure to vent this boiler in accordance with these instructions could cause products of combustion to enter the building resulting in severe property damage personal injury or death Do not interchange vent systems or materials unless otherwise specified The use of thermal insulation covering vent pipe and fittings is prohibited Do not use a barometric damper draf...

Page 17: ...17 106375 01 4 16 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 18: ...ermination fittings are never counted 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 155MBH model which has the following compo...

Page 19: ...piping 5 8 per foot For Category I II and IV boilers have horizontal runs sloping upwards not less than 1 4 inch per foot 21 mm m from the boiler to the vent terminal 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 ...

Page 20: ...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 21: ...21 106375 01 4 16 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 22: ...t 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 Diversitech Low Prof...

Page 23: ...03 or ISEP0339 w screen Intake Elbow w screen Note 3 Elbow w screen Note 3 Elbow w screen Elbow w screen Elbow w screen Elbow w screen Elbow w screen Elbow w screen Terminal Option B Ipex Low Profile Ipex 196984 Ipex 196985 Not Permitted Not Permitted Not Permitted Not Permitted Not Permitted Not Permitted Terminal Option C Diversitech HVENT HVENT 2 HVENT 3 Not Permitted Not Permitted Not Permitte...

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

Page 25: ...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 26: ...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 27: ... Note Air intake termination not shown refer to Venting Section in 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 28: ... rodent screens is generally recommended for both terminations Two rodent screens suitable for 3 PVC terminals are installed as shown in Figure 7 28 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 DuraVent 3PPS BG 2 P...

Page 29: ...0UV or 2PF 39UV w Screen 3PF 10UV or 3PF 39UV w Screen ISEP02 or ISEP0239 w Screen ISEP03 or ISEP0339 w Screen Intake 180 Elbow w Screen 180 Elbow w Screen 180 Elbow w Screen 180 Elbow w Screen 180 Elbow w Screen 180 Elbow w Screen 180 Elbow w Screen 180 Elbow w Screen Terminal Option I Ipex FGV Concentric Ipex 196105 Note 3 Ipex 196006 Note 3 Not Permitted Not Permitted Not Permitted Not Permitte...

Page 30: ...t 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 intake Flex ...

Page 31: ... 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 32: ...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 33: ...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 34: ...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 35: ... 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 36: ... 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 Reliable operation of this boiler canno...

Page 37: ...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 38: ... 2PPS 36B w Screen 3PPS 12B or 3PPS 36B w Screen 2PF 10UV or 2PF 39UV w Screen 3PF 10UV or 3PF 39UV w Screen Intake 90 Elbow w Screen 90 Elbow w Screen 90 Elbow w Screen 90 Elbow w Screen 90 Elbow w Screen 90 Elbow w Screen Flex Termination Components Masonry Chimney Chase Note 3 Vent Not Permitted Intake Flex Termination Components B Vent Chimney Chase Vent Not Permitted Intake Note 1 Max vent le...

Page 39: ...S FK 2PPS FLEX 3PPS FK 3PPS FLEX 2PF FLEX KIT 2PF FLEX 3PF FLEX KIT 3PF FLEX IFCK02 IFCK03 90 Elbow w Screen 90 Elbow w Screen 90 Elbow w Screen 90 Elbow w Screen 90 Elbow w Screen 90 Elbow w Screen Not Permitted 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 ...

Page 40: ...75 01 4 16 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 106375 01 4 16 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 16 VII Venting D Design Requirements Unique to Split Vent Systems continued Figure 7 25 Masonry Chimney Chase Requirements DANGER Venting of Other Appliances Or Fire place into Chase or Adjacent Flues Prohibited ...

Page 43: ...ce the first piece of 3 CPVC installed in Step b to 2 CPVC using a CPVC reducing coupling or elbow Otherwise assemble the 3 CPVC elbow and the remainder of the 30 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...

Page 44: ...to 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 piping and all types of construction d To the extent possible pitch horizontal ai...

Page 45: ...45 106375 01 4 16 Figure 7 28 Installation of Standard Vertical Terminals Figure 7 27 Installation of Standard Horizontal Terminals VII Venting E Assembly of CPVC PVC Vent Systems continued ...

Page 46: ... Slide both vent 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 supp...

Page 47: ...1 4 16 Figure 7 30 Installation of Diversitech Low Profile Terminal Through Sidewall Figure 7 29 Installation of IPEX Low Profile Terminal Through Sidewall VII Venting E Assembly of CPVC PVC Vent Systems continued ...

Page 48: ...4 16 VII Venting E Assembly of CPVC PVC Vent Systems continued Figure 7 32 Installation of IPEX and Diversitech Concentric Terminal through Sidewall Figure 7 31 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: ... The vent adaptor has two different inside diameters The smaller lower inside diameter accepts 3 nominal PolyPro Figure 7 26 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 Tighten clamp on vent adapter to secure vent pipe b If 2 PolyPro is to be used for the vent system reduce the first piece of 3 PolyPr...

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 35 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 36 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 38 Installation of Duravent PolyPro Concentric Vent Terminal Through Sidewall VII Venting F Assembly of DuraVent PolyPro Vent Systems continued Figure 7 39 Installation of Duravent PolyPro Concentric Terminal Through Roof ...

Page 55: ...for the male threads Secure the adaptor to the cap using a 2 or 3 electrical conduit lock nut Seal all joints with RTV G Assembly of Selkirk Polyflue Vent Systems 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 ...

Page 56: ... 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 42 If a 180 bend is used install the rodent screen in the open side of the bend using a ring made of PVC pipe If desired the termination fittings can be attached to the...

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 41 Installation of Selkirk Polyflue UV Resistant Single Wall Horizontal Terminal Figure 7 42 Installation of Selkirk Polyflue UV Resistant Single Wall Vertical Terminal ...

Page 59: ...e smaller lower inside diameter accepts 3 nominal InnoFlue Figure 7 26 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 Clamp on vent adapter to secure vent pipe b If 2 InnoFlue is to be used for the vent system reduce the first piece of 3 InnoFlue installed in Step a to 2 using Centrotherm ISRD0302 Oth...

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 44 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 45 Installation of Centrotherm InnoFlue UV Stabilized Single Wall Vertical Terminal VII Venting H Assembly of Centrotherm InnoFlue Vent Systems ...

Page 62: ...installation manual 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 2 or 3 depending on the Vent Option Cut a clearance hole in the cap for the male threads Secure the adaptor to the cap using a 2 or 3 electrical conduit lock nut Seal all joints with RTV I Condensate Trap and Drain Line All condensate which forms in the...

Page 63: ...re 7 46 Condensate Trap Installation 8 If the point of condensate disposal is above the trap it will be necessary to use a condensate pump to move the condensate to the drain In such cases select a condensate pump that is approved for use with condensing boilers If overflow from this pump would result in property damage select a pump with an overflow switch and use this switch to shut down the boi...

Page 64: ...enting 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 ...

Page 65: ...ler 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 A...

Page 66: ...er 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 1 Gas Connection to Boiler 3 MIN DRIP LEG INTERNAL FACTORY SUPPLIED MANUAL SHUT OFF VALV...

Page 67: ...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 frequent additions of h...

Page 68: ...for the system to work properly See next section for more information 4 Expansion Tank required If this boiler is replacing an existing boiler with 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 ma...

Page 69: ...Ball Valve Ball Valve Temperature Pressure Gauge Drain Valve Return Inlet Supply Outlet INLET TOP OUTLET TOP Automatic Air Vent Temperature Pressure Gauge Relief Valve Drain Valve Copper Piping Cap Return Inlet Supply Outlet Ball Valve Ball Valve Figure 9 1 Near Boiler Piping NOTICE For combi model K2FTC 155 only the inlet bottom outlet bottom piping configuration may be used Refer to Appendix C f...

Page 70: ...quires that the water flow rate through it remain within the limits shown in Table 9 3 any time the boiler is firing At flow rates below the minimum shown the boiler s temperature rise limit function may prevent the boiler from firing Flow rates through the boiler in excess of the maximum shown in Table 9 3 can result in excessive noise or erosion damage to piping There are two basic methods that ...

Page 71: ...ure that the boiler will have the required flow shown in Table 9 3 regardless of the flow in the heating system 1 System Loop Piping Size the system circulator and 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 syst...

Page 72: ... 19 1 5 6 0011 K2FT 270 1 14 3 3 5 0010 16 7 4 6 0010 20 1 6 4 0011 25 1 9 7 0013 Table 9 5b Recommended Grundfos Circulators for 60 Equivalent ft Boiler Loop Piping Boiler Model Minimum Pipe Size in T 35 F T 30 F T 25 F T 20 F Flow GPM Boiler Piping Head Loss ft Circulator Model Flow GPM Boiler Piping Head Loss ft Circulator Model Flow GPM Boiler Piping Head Loss ft Circulator Model Flow GPM Boil...

Page 73: ...Table 9 3 IX System Piping continued Table 9 6 Fitting and Valve Equivalent Length Copper Fitting and Sweat Valve Equivalent Length Ft Fitting or Valve Description Copper Pipe or Valve Size 1 1 1 2 90 Elbow 2 5 3 0 4 0 5 5 45 Elbow 1 0 1 2 1 5 2 0 Tee through flow 0 5 0 6 0 8 1 0 Tee Branch flow 4 5 5 5 7 0 9 0 Diverter Tee typical 23 5 25 0 23 0 23 0 Gate Valve 0 3 0 4 0 5 0 7 Globe Valve 25 0 36...

Page 74: ... diameters upstream of first tee A No further apart than 12 30 cm or four pipe diameters whichever is smaller B At least 18 46 cm of straight pipe for Conventional Air Scoop C Secondary Unions Not Required Optional Location Shown Boiler Circulator Full Port Isolation Valves To System Optional Zone Valve Controlled System Heating System Circulator System Zone Valves Figure 9 7a Piping Method 1 Near...

Page 75: ... Line Y Strainer Recommended From System Full Port Isolation Valves Indirect Circulator Relief Valve Drain Valve Secondary Unions Not Required Optional Locations Shown Full Port Isolation Valves Flow Check Indirect Supply Indirect Return Indirect Domestic Water Heater IWH At least eight pipe diameters upstream of first tee A No further apart than 12 30 cm or four pipe diameters whichever is smalle...

Page 76: ... Header Sensor As Close As Possible To Downstream Tee Y Strainer Recommended Secondary Unions Not Required Optional Location Shown Drain Valve Relief Valve Header Temperature Sensor When Used Indirect Domestic Water Heater IWH Boiler Circulator Full Port Isolation Valves To System System Zone Valves Heating System Circulator Optional Zone Valve Controlled System Hydraulic Separator May Be Substitu...

Page 77: ...wn Relief Valve Drain Valve From System At least eight pipe diameters upstream of first tee A No further apart than 12 30 cm or four pipe diameters whichever is smaller B At least 18 46 cm of straight pipe for Conventional Air Scoop C Boiler Circulator Full Port Isolation Valves To System Heating System Circulator System Zone Valves Optional Zone Valve Control System IX System Piping continued Fig...

Page 78: ...least eight pipe diameters upstream of first tee A No further apart than 12 30 cm or four pipe diameters whichever is smaller B At least 18 46 cm of straight pipe for Conventional Air Scoop C Boiler Circulator Flow Check Optional Full Port Isolation Valve Heating Circulators Optional Full Port Isolation Valve To System Heating System Circulator System Zone Valves Optional Zone Valve Controlled Sys...

Page 79: ...uired Optional Locations Shown Drain Valve Heating Circulators Flow Check To System Full Port Isolation Valve At least eight pipe diameters upstream of first tee A No further apart than 12 30 cm or four pipe diameters whichever is smaller B At least 18 46 cm of straight pipe for Conventional Air Scoop C Full Port Isolation Valves Boiler Circulator To System Heating System Circulator System Zone Va...

Page 80: ...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 minimum required w...

Page 81: ...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 boiler 3 Air Handlers Where the boiler is connected to air handler...

Page 82: ...NING 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 boiler may result in serious physical ha...

Page 83: ...LA See Section XII Operation for information on setting up the pump operation 2 Low Voltage Field 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 thermostat C 24V Common DHW T Stat 24VA...

Page 84: ...250 V 6 3 A Slow Blow 5x20mm N L N L N L N L G OUTDOOR SENSOR HONEYWELL 32003971 003 HEADER SENSOR if used TO MODBUS DEVICE if used 24 VOLT HEATING THERMOSTAT DHW THERMOSTAT if used EXTERNAL LIMIT S if used TO ALARM SYSTEM EnviraCOM THERMOSTAT Optional Replaces Heating Thermostat By Others 1 REMOVE THIS JUMPER IF EXTERNAL LIMIT IS USED 1 Low Voltage Connections Fuse F1 250 V 1 6A Slow Blow 5x20mm ...

Page 85: ...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 Operation for information on enabling the outdoor reset sensor e Header Sensor When this sensor is installed and enabled the boiler will attempt to maintain the target water temperature in the header rathe...

Page 86: ...m Heating Circulators DETAIL B SCALE 1 4 Header Temperature Sensor Honeywell 32003971 003 Well Should Extend Into Header Flow As Far As Possible Use Extension Only If Necessary Close Nipple Locate Header Sensor As Close As Possible To Downstream Tee Downstream Primary Secondary Tee Honeywell Immersion Well ...

Page 87: ...87 106375 01 4 16 Figure 10 5 Internal Wiring Ladder Diagram X Wiring continued ...

Page 88: ...88 106375 01 4 16 X Wiring continued ...

Page 89: ...WIRE 105 C LOW VOLTAGE FIELD WIRING LINE VOLTAGE FACTORY WIRING SIZE 18 AWG TYPE TEW AWM STRANDED WIRE 105 C LINE VOLTAGE FIELD WIRING IGNITER WIRE 250 C WIRE COLOR CODE BK BLACK BL BLUE BR BROWN GR GREEN GY GRAY OR ORANGE PI PINK RD RED VI VIOLET WH WHITE YE YELLOW R G RED W GRAY TRACKER B G BLUE W GRAY TRACKER P G PINK W GRAY TRACKER Y G YELLOW W GRAY TRACKER V G VIOLET W GRAY TRACKER WIRING LEG...

Page 90: ... L N 120V DHW AQUASTAT Low Voltage Connections Fuse F1 250 V 1 6A Slow Blow 5x20mm EnviraCOM MODBUS Boiler To Boiler Communication Network V B A Header Sensor Outdoor Sensor Heat T stat DHW T stat External Limit Alarm Spare Fuse 120 VAC Connections Pump Fuse 120 V Line System Pump DHW Pump Boiler Pump Spare Pump Fuse POWER INPUT ZONE 4 ZONE 3 ZONE 2 ZONE 1 120 VOLT CIRCULATORS ZR ZC X X END SWITCH...

Page 91: ...FF 4 MIN 24 HR OFF SLAVE PRIORITY ON RESET PRIMARY PUMP ON POST PURGE ON PRIOR PROTECT ON PUMP EXERCISE ON 30 SEC 2 WK LOW LIMIT ZC ON MAIN PRIORITY X X X X END SWITCH EXPANSION ZONE 1 ZONE 2 ZONE 3 ZONE 4 NET A B C C W R R R R 1 W W W C C C 2 THERMOSTATS 24 VAC PRIORITY BT LT ZC4 ZC3 ZC2 ZC1 1 2 3 OFF ON ZONE CONTROL CIRCULATOR PANEL CAT 5 Cable Supplied with Zone Control HEATING THERMOSTATS RJ45...

Page 92: ...l 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 LP Gas propane convert as described in Appendix A If boiler is operating at elevations above 4 500 ft see Appendix B of this manual for setup instructions ...

Page 93: ...tructions for required dosage In general these products 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 manufa...

Page 94: ...uipped 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 The boiler may be temporarily locked into high or low fire as follows a Fire the boiler through any call for heat b From the Home Screen press ADJUST to enter the adjust menu c Press ADJUST d Press LOGIN e Press 000 f Enter the password 086 g ...

Page 95: ...375 01 4 16 Figure 11 2 Burner Flame XI Start Up and Checkout continued Figure 11 1a Home Screen at Power Up No Call for Heat Figure 11 1b Home Screen on Heat Demand Figure 11 1c Home Screen with Active Fault ...

Page 96: ...e 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 or loss of life due to carb...

Page 97: ...anty a copy of which is included with this boiler It is the responsibility of the installing contractor to see that all controls are correctly installed and are operating properly when the installation is complete WARNING All combustion performance numbers MUST be verified with a combustion analyzer Failure to do so will result in substantial property damage severe personal injury or death Table 1...

Page 98: ...98 106375 01 4 16 Operating Instructions XI Start Up and Checkout continued ...

Page 99: ...e heating load decreases This boiler is not used for any space heating This boiler is part of a modular or multiple boiler system having a total input of 300 000 BTU hr or greater This boiler is equipped with a tankless coil 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 ...

Page 100: ...mand The Control accepts a call for heat demand from multipleplacesandrespondsaccordingtoit s Priority Whenmorethan1demandispresentthehigherpriority demand is used to determine active boiler settings 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...

Page 101: ...oiler Protection Features 1 Supply Water Temperature High Limit The control is equipped with internal operating control and high limit features The control monitors a dual element temperature sensor that is mounted in the supply water manifold and provides UL353 and UL1998 internal safety algorithms If supply water temperatureincreasesabovetheactivesetpointplusdiff above default 190 F 87 7 C the b...

Page 102: ... Control only controls the system and boiler circulators individual zones are not protected It is recommended that the boiler be installed in a location that is not exposed to freezing temperatures D Multiple Boiler Control Sequencer 1 Plug Play Multiple Boiler Control Sequencer When multiple boilers are installed the Control s Sequencer may be used to coordinate and optimize the operation of up t...

Page 103: ...tial firing rate is 100 2 or 50 when the third boiler is started the firing rate starts at 200 3 or 66 After the initial start the Sequence Master develops a unison firing rate demand based on it s setpoint and sensed header temperature 10 Innovative Condensing Boiler Control Duringlowloads theSequenceMasterlimitsfiringrates to a Base Load Common Rate to ensure modulating condensing boiler peak op...

Page 104: ...circulator s On After flame is proven the sequence continues with run stabilization and low fire hold time Once the field adjustable low fire hold time is completed normal boiler operation begins modulation rate depending on temperature and setpoint selections Priority Domestic Hot Water Status Running If the Central Heat call for heat is active and a Domestic Hot Water DHW call for heat received ...

Page 105: ...symbol will always return the display to the Home screen Arrow Symbol The Arrow symbol links together all screens in the selected group For example repeated pressing the right Arrow symbol will rotate the display around all the screens in the Status group Using this feature the user can review all the boiler status and adjustment mode screens Fault Symbols Active Fault and Rate Limit symbols provi...

Page 106: ...y repeatedly selecting the right or left arrow symbol These screens are accessed by selected the Status button from the Home screen XII Operation E Boiler Sequence Of Operation continued Figure 12 6 Status Screens Figure 12 7 Boiler Status Screen Definitions NOTE Only visible if Zone Panel is connected Zone Panel 1 and 2 shown typical for 1 through 4 ...

Page 107: ...tatus of Frost Protection and pump Exercise functions 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 th...

Page 108: ...rovide in depth operating parameter status such as On Point Off Point and Setpoint Source information Demand specific details are provided for Central Heat Auxiliary Heat Domestic Hot Water and the Sequence Master demands and outdoor air reset Sequencer screens are only shown when the Sequence Master is enabled 4 Detail Screens XII Operation E Boiler Sequence Of Operation continued Auxiliary Heat ...

Page 109: ...creens When the Sequence Master is enabled the following screen is available The Sequencer Status screen is selected by pressing Status button from the Home screen when Sequence Master is enabled XII Operation E Boiler Sequence Of Operation continued ...

Page 110: ...Installer Password is 86 and press the return arrow to close the keypad Press the Save button Press the Adjust button to enter Adjustment mode Figure 12 9 Adjust Mode Screens 2 Adjusting Parameters Editing parameters is accomplished as follows Login to Access Adjustment Mode For Service Contact CONTRACTOR NAME ADDRESS LINE 1 ADDRESS LINE 2 PHONE NUMBER Contractor Adjust Access Level Installer Adju...

Page 111: ...rost Protection is not used Enable Boiler and system circulators start and boiler fires when low outside air supply and return temperatures are sensed Disabled Enable Disable Warm Weather Shutdown Enable Disable Warm Weather Shutdown WWSD is not used Enable The boiler and pumps will not be allowed to start in response to a central heat call for heat if the outside temperature is greater than the W...

Page 112: ...Rate fan speed setting to limit the boiler output accordingly 100 Minimum to Maximum Heat Rate Domestic Hot Water DHW Max 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 maximum output of the boiler change the DHW Maximum Expected Heat Rate fan spe...

Page 113: ...RPM 1600 1750 2000 Model K2FTC 155N 46 Maximum Heat Rate RPM 6500 Minimum Heat rate RPM 1600 Model K2FTC 155P 46 Maximum Heat Rate RPM 6900 Minimum Heat rate RPM 1600 Altitude 6 001 7 800 Ft Model K2FT 085N 67 K2FT 110 67 K2FT 155 67 K2FT 205N 67 K2FT 270N 67 Maximum Heat Rate RPM 6500 6900 7100 6800 6750 Minimum Heat rate RPM 1700 1700 1600 1600 1700 Model K2FT 085P 67 K2FTC 155 67 K2FT 205P 67 K...

Page 114: ... rates for the active turned on zones After establishing the maximum heat rate the Control then measures water temperature and fires the boiler only as hard as required for the heat demand Expected Heat Rate Adjustment Screens HeatMatch Software Example call for heat durations for a four zone house Maximum heat rate limits firing rate and prevents the Control from firing to 100 in response to a sm...

Page 115: ...Demand Never Any Demand Header Sensor Demand CH Off for DHW Boiler Pump run pump for Activates the boiler pump output according to selected function Never Pump is disabled and not shown on status screen Any Demand Pump Runs during any call for heat Header Sensor Demand Pump Runs when boiler is firing and when there is DHW demand Selected when Header Sensor is selected as modulation sensor and boil...

Page 116: ...ible for the domestic and system pumps to run at the same time The boiler pump must run for every call for heat CAUTION It is the installers responsibility to select boiler piping configurations that provide the proper flow rates and performance for the boiler and indirect water heater B C A Flow Check Optional Full Port Isolation Valves Optional Full Port Isolation Valves Heating Circulators To S...

Page 117: ...ast eight pipe diameters upstream of first tee A No further apart than 12 30 cm or four pipe diameters whichever is smaller B At least 18 46 cm of straight pipe for Conventional Air Scoop C Boiler Circulator To System Heating System Circulator System Zone Valves Optional Zone Valve Controlled System CAUTION It is the installers responsibility to select boiler piping configurations that provide the...

Page 118: ... optional It is permissible for the domestic and system pumps to run at the same time The boiler pump must run for every call for heat Example Pump Parameter selections continued XII Operation F Changing Adjustable Parameters continued Sequencer Master Boiler 1 Boiler 2 Wiring locations Thermostat X DHW call for heat X System pump X DHW pump X Boiler Pump X X Sequencer Master Parameter Selections ...

Page 119: ... 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 120: ...ture controller Proportion Integral Derivative PID values Higher values cause a larger firing rate change for each degree of temperature change If set too high firing rate overshoots required value increases to high fire causing the temperature to exceed the Diff Above setpoint and cycle the boiler unnecessarily Lower values cause a smaller firing rate change for each degree of temperature change ...

Page 121: ...ng the temperature to exceed the Diff Above setpoint and cycle the boiler unnecessarily Lower values cause a smaller firing rate change for each degree of temperature change If set too low the firing rate response will be sluggish and temperature will wander away from setpoint Disable Disable Enable Auxiliary Priority Over Central Heat This parameter allows the Auxiliary Heat demand to be higher o...

Page 122: ... rate response will be sluggish and temperature will wander away from setpoint 10 seconds 0 to 300 seconds Low Fire Hold Time Low Fire Hold Time is the number of seconds the control will wait at low fire modulation rate before being released to modulate After ignition and flame stabilization periods the firing rate is held at low fire for Low Fire Hold Time This delay allows heat to travel out to ...

Page 123: ...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 124: ...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 125: ...7 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 XII Operation F Changing Adjustable Parameters continued ...

Page 126: ...pond to rapid load increases 70 50 100 Base Load Common Rate To maximize condensing boiler efficiency the firing rate is limited to an adjustable value Boilers are kept at or below this firing rate as long as the boilers can handle the load After last available boiler has started the modulation rate limit is released up to 100 3 1 5 Response Speed This parameter adjusts the Sequence Master tempera...

Page 127: ...ng two parameters may be used to adjust the signal range Modbus Modbus is used as the temperature setpoint 130 F 54 4 C 80 F 26 7 C Central Heat Setpoint Central Heat 4 20mAdc Setup 4 mA Water Temperature Sets the Central Heat Temperature Setpoint corresponding to 4mA for signal input on Control Terminals J8 6 and J10 8 Current below 4mA is considered invalid failed or incorrect wired input 180 F ...

Page 128: ...sleeved loose fitting clothing 3 Gloves 4 Eye Protection Take steps to assure adequate ventilation Wash all exposed body areas gently with soap and water after contact Wash work clothes separately from other laundry and rinse washing machine after use to avoid contaminating other clothes Discard used RCF components by sealing in an airtight plastic bag RCF and crystalline silica are not classified...

Page 129: ...vy 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 ...

Page 130: ...hat the gas shutoff shown in Figure 8 1 is closed e Disconnect the flexible gas line at the gas valve flare connection Figure 13 1 f Unplug the electrical connection to the gas valve g Disconnect the air proving switch tube from the gas valve outlet tap h Unplug the power and speed control cables from the blower NOTICE Warranty does not cover boiler damage or malfunction if the following steps are...

Page 131: ...ible Gas Line Figure 13 2 Igniter and Flame Sensor Location XIII Service and Maintenance continued Flame Sensor Igniter Flexible Gas line Connection When disconnecting flexible gas line place a backup wrench on this nut to prevent damage to gas valve ...

Page 132: ...ter in the trap Unscrew the cap Flush any debris found in the trap with water do not use other cleaning agents Reassemble the trap as shown in Figure 13 4 XIII Service and Maintenance continued WARNING Asphyxiation Hazard Do not operate the boiler without the float in place Doing so could result in flue gas leakage into the indoors resulting in personal injury or death from Carbon Monoxide CO pois...

Page 133: ...ntinued CONDENSATE TRAP BRACKET CONDENSATE TRAP COLLAR BOILER JACKET CONDENSATE DRAIN CORRUGATED DRAIN TUBE INLET NUT INLET GASKET OUTLET NUT CONDENSATE TRAP 10 32 SHCS 10 SPLIT LOCK WASHER 10 32 HEX NUT 8 18 THREAD FORMING SCREW 1 4 LONG VENT CLEAN OUT CAP GASKET FOR CLEAN OUT CAP CLEAN OUT CAP NUT 0 177in 0 02 4 5mm 0 5 ...

Page 134: ... Turn the boiler off immediately Failure to do so could cause severe heat exchanger damage v Follow ALL instructions in Section XI Start up and Checkout to place the boiler back in service including the performance of a combustion test 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 1435...

Page 135: ... 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 Dark Fan off LWCO lights off no green power light on Control No 120Vac Power at Boiler Check breaker and wiring between breaker panel and boiler Blown high voltage fuse Replacement Fuse Kit part numb...

Page 136: ...s lost communication with the Sequence Master Check the following RJ 45 peer to peer network disconnected Sequencer Master was Enabled and 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 blo...

Page 137: ...e firing rate is limited or reduced to help avoid a lockout or save energy Refer to Hard Lockout section for corrective actions High Stack Temperature Limit High Supply Temperature Limit High Differential Temperature Limit The following messages appear as part of normal start and stop sequences Minimum Modulation normal start stop sequence Low Fire Hold Rate Low fire hold rate is a normal start up...

Page 138: ...cked Flue Inlet Switch Special Note Before a call for heat the air pressure switch is closed When there is a call for heat with a blocked vent the air pressure switch will open due to excessive pressure of the blower against a blocked flue pipe after the blower starts The control stops the start sequence and stops the blower After the blower stops the pressure switch re closes and the cycle contin...

Page 139: ...ng for blower speed to match purge and light off setpoint Normal waiting for blower speed to match purge and light off setpoint 27 Undefined Fault Undefined Fault Consult Factory 28 or 53 Air Proving Switch Failed to Close Air Proving Switch Failed to Close The air proving switch has failed to close Check switch check switch connection and wiring Blocked vent blocked inlet blocked or disconnected ...

Page 140: ...ged drain line in trap 18 Light off rate proving failed Blower is not running at Light off rate when it should or blower speed signal not being detected by Control Loose connection in 120 VAC blower wiring Loose or miswired blower speed harness Defective blower 19 Purge rate proving failed Blower is not running at Purge rate when it should or blower speed signal not being detected by Control Loose...

Page 141: ...h your local U S Boiler Wholesale distributor Should you require assistance in locating a U S Boiler distributor in your area or have questions regarding the availability of U S Boiler products or repair parts please contact U S Boiler Customer Service at 717 481 8400 or Fax 717 481 8408 ...

Page 142: ...and hardware 105798 01 1H Igniter Repair Kit includes electrode gasket and hardware 103005 02 1I Heat Exchanger Flue Gasket Repair Kit 107000 01 107000 02 1J Flue Pipe Repair Kit includes pipe and gasket 106998 01 106998 02 1K Flue Pipe Gasket Repair Kit 106999 01 1L Silicone Tubing Repair Kit 106989 01 1M Flue Inlet Switch Repair Kit 106988 01 105857 01 106988 02 1N Condensate Trap Repair Kit 106...

Page 143: ...143 106375 01 4 16 XV Repair Parts continued 1H 1G 1F 1J 1E 1D 1C 1B 1M 1L 1N 1S 1T 1V 1R 1W 1U 1Q 1P 1O 1A 1K 1I 1U Space Heating Models K2FT 085 K2FT 110 K2FT 155 K2FT 205 K2FT 270 ...

Page 144: ... 4 NPT Drain Valve 806603061 2T Temperature Pressure Gauge Repair Kit 105894 01 2U Water Gasket Repair Kit supply and return pipes includes 2 gaskets 106995 01 2V Supply Pipe Assembly Repair Kit includes pipe assembly zone valve body gasket and jacket grommet 106977 03 2W Return Pipe Assembly Repair Kit includes pipe assembly gasket and jacket grommet 106978 01 2X Zone Valve Actuator 106847 01 2Y ...

Page 145: ... 2E 2D 2C 2B 2M 2L 2N 2A 2H 2F 2I 2J 2K 2O 2P 2Q 2R 2S 2T 2W 2U 2V 2U 2BB 2AA 2HH 2DD 2EE 2CC 2Y 2FF 2GG 2Z 2GG 2Z 2BB 2GG 2GG 2GG 2II 2X XV Repair Parts continued Combi Domestic Hot Water and Space Heating Model K2FTC 155 ...

Page 146: ... 107005 05 3F Venturi Cork Gasket 106082 01 3G Gas Valve Repair Kit includes gas valve inlet and outlet seals and hardware 107006 01 3H Gas Valve 90 Inlet Flange Repair Kit 107007 01 3I Gas Valve Flange Adapter 5 8 OD Flare x 1 2 NPT 106363 01 3J Gas Valve Wire Harness Repair Kit 107008 01 3K Gas Flex Tube Repair Kit 107009 01 3L Gas Shutoff Valve Repair Kit 107010 01 3M Gas Pipe 1 2 Sch 40 x 22 L...

Page 147: ...147 106375 01 4 16 XV Repair Parts continued 3A 3B 3C 3D 3F 3E 3G 3H 3O 3P 3Q 3R 3J 3K 3I 3M 3N 3L All Models ...

Page 148: ... Clamp 106162 01 4H Gas Pipe Clamp and Hanging Bracket Screw 1 4 20 x 1 2 Long Type F Self Tapping 80860700 4I Door Latch Keeper 106146 01 4 4J Water Pipe Grommet 106139 01 4 103252 01 4 4K Vent Connector Repair Kit includes connector gaskets and hardware 107034 01 4L Air Intake Connector Repair Kit includes connector gasket and locknut 107017 01 4M Air Intake Shield 106389 01 4N Right Side Panel ...

Page 149: ...149 106375 01 4 16 4A 4C 4B 4D 4G 4I 4J 4K 4L 4M 4Q 4N 4R 4J 4P 4O 4F 4H 4E 4H 4E 4S XV Repair Parts continued Space Heating Models K2FT 085 K2FT 110 K2FT 155 K2FT 205 K2FT 270 ...

Page 150: ...e Clamp and Hanging Bracket Screw 1 4 20 x 1 2 Long Type F Self Tapping 80860700 5I Door Latch Keeper 106146 01 2 5J Water Pipe Grommet 106139 01 3 5K Vent Connector Repair Kit includes connector gaskets and hardware 107034 01 5L Air Intake Connector Repair Kit includes connector gasket and locknut 107017 01 5M Air Intake Shield 106389 01 5N Right Side Panel Assembly w Gaskets 106715 01 5O Condens...

Page 151: ...151 106375 01 4 16 XV Repair Parts continued Combi Domestic Hot Water and Space Heating Model K2FTC 155 5A 5B 5C 5D 5E 5E 5F 5G 5H 5H 5H 5I 5J 5J 5K 5L 5M 5N 5O 5P 5Q 5R 5T 5S ...

Page 152: ...s PCB fuses and screws 107020 01 6F High Voltage PCB Cover 106934 01 6G Repair Programmed Control 107093 01 6H Control Foot Gasket 105109 01 4 6I Low Voltage PCB Repair Kit includes PCB fuse and screws 107035 01 6J PCB and Latch Keeper Screw 8 32 x 3 8 Long Machine Screw 106538 01 12 6K Wire Harness Tie Gasket 105110 01 4 6L User Interface Inner Plastic Trim 106380 01 6M Programmed Display Repair ...

Page 153: ...153 106375 01 4 16 XV Repair Parts continued 6D 6B 6A 6E 6I 6G 6L 6N 6H 6C 6K 6M 6C 6C 6J 6J 6F All Models ...

Page 154: ...ling Vent Termination 101870 01 Not Permitted 7F 2 SS Termination Screen 102191 04 2 Not Permitted 7G 2 x 3 CPVC Reducing Bushing 106611 01 Not Permitted 7H 2 x 3 PVC Reducing Bushing 106619 01 Not Permitted 7A 7D 7C 7B 7G 7H 7F 7E 3 CPVC PVC Sidewall Vent Components Key No Description Part Number Qty K2FT 085 K2FT 110 K2FT 155 K2FTC 155 K2FT 205 K2FT 270 7A 3 PVC Sidewall Vent Kit includes items ...

Page 155: ...s Repair Kit 107037 01 8C Ignition Cable Harness Repair Kit 107038 01 8D Blower Control Harness Repair Kit 4 wire harness 107002 01 8E Blower Power Harness Repair Kit 3 wire harness 107003 01 8F DHW to Circulator and Zone Valve Harness Repair Kit 107004 01 8G Gas Valve Harness Repair Kit 107008 01 not shown LWCO Jumper Repair Kit 105908 01 not shown Outdoor Temperature Sensor not shown 102946 01 n...

Page 156: ...r 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 is not followed exactly a fire an explosion or production of carbon monoxide may result causing property damage...

Page 157: ...noxide poisoning 3 Before attempting to start the boiler turn the throttle Figure A 3 clockwise until it stops several full turns 4 Turn throttle counter clockwise the exact number of turns shown in Table A 4 5 Attempt to start the boiler using the operating instructions located on Page 98 If the boiler does not light on the first try for ignition allow to boiler to make at least four more attempt...

Page 158: ...of Throttle Turns for Conversion to LP Gas Appendix A continued WARNING All combustion performance numbers MUST be verified with a combustion analyzer Failure to do so will result in substantial property damage severe personal injury or death Offset Regulator Do Not Adjust Tube to Air Proving Switch Gas Outlet Throttle Screw Outlet Tap Gas Inlet Inlet Tap ...

Page 159: ...10 9 5 11 0 4 2 6 5 155 9 5 11 0 4 2 6 5 205 9 5 11 0 4 2 6 5 270 9 5 11 0 4 2 6 5 Table A 5 Acceptable Combustion Readings for LP Operation 0 4 500 ft 9 Verify that the gas inlet pressure is between 8 0 and 14 0 inches w c with all gas appliances including the converted boiler both on and off 10 A sheet of yellow labels is provided in the envelope with this manual for boilers converted from natur...

Page 160: ...ng for LP see Table B 5 3 Start boiler as described in boiler Installation manual and lock boiler in high fire See XI Startup and Checklist If boiler does not light turn throttle screw in 1 8 turn increments in a counterclockwise direction until boiler fires Do not stop here follow Steps 4 7 Verify that the gas inlet pressure is between the following limits with all gas appliances including the co...

Page 161: ...below 200 ppm while ensuring CO2 remains in the range specified in Table B 3 If CO Air Free is still above 200 ppm reduce fan speed in 100 rpm increments until CO Air Free is less than 200 ppm 6 Start boiler five times at the above settings to ensure boiler lights off without delay and without noise Check CO2 and CO Air Free to ensure that the CO2 is within the range specified in Table B 3 and CO ...

Page 162: ...1 2 K2FT 205 NG 2 0 K2FT 205 LP 2 6 K2FT 270 NG LP 3 4 De rate s per 1000 ft are approximate Based on minimum vent length 0 2000 ft is Sea Level Input Rate 2000 4500 ft derate 1 7 1000 ft Altitude Model Natural Gas CO2 LP Gas CO2 Max CO Air Free 4 501 ft to 6000 ft K2FT 085 9 5 9 9 10 0 10 7 COAF readings must be less than 200 ppm K2FT 110 9 5 9 8 10 0 10 4 K2FT 155 9 5 9 7 10 0 10 4 K2FT 205 9 5 ...

Page 163: ...ice Sizes Field Installed Model Size LP Gas Orifice Dia 85 not used 110 not used 155 not used 205 0 224 in 270 0 224 in Model Fuel HF Target FS RPM LF Target FS RPM 4501 6000 ft 6001 7800 ft 7801 10 100 ft 4501 6000 ft 6001 7800 ft 7801 10 100 ft K2FT 085 NG 6100 6650 7200 1600 1700 1800 LP 6100 7000 7200 1600 1700 1800 K2FT 110 NG 6450 6900 7200 1600 1700 1800 LP 6450 6900 7200 1600 1700 1800 K2F...

Page 164: ... exchanger and DHW through a flat plate heat exchanger DHW is activated by a flow switch Water temperatures are regulated by the boiler controls and a thermostatic mixing valve III Specifications K2FTC 155 Boiler Input Rate 155MBH Compatible Boiler Control Control or higher Thermostatic Mixing Valve Adjustable 70 F 21 C 145 F 63 C ASSE 1017 Certified Minimum Flow to Operate 0 5 gpm 2 l min Lead Co...

Page 165: ...llation regulations enforced in the area where the installation is to be made These regulations shall be carefully followed in all cases Authorities having jurisdiction shall be consulted before installations are made All wiring on boilers installed in the USA shall be made in accordance with the National Electrical Code and or local regulations ...

Page 166: ...nance can cause property damage personal injury or loss of life Read and understand the entire K2FT boiler manual before attempting installation start up operation or service Installation and service must be performed only by an experienced skilled and knowledgeable installer or service agency Failure to properly install adjust service or pipe this Combi may result in improper operation causing da...

Page 167: ...boiler shown in Figure C 2 Please note there is no top and bottom supply return connection available on combi 155 boiler only bottom supply and return piping 4 Install DHW piping included in miscellaneous parts carton See pages 169 and 170 for DHW pipe assembly Correctly pipe domestic side in out connections using check valve relief valve and expansion tank as described in Figure C 2 5 Complete wi...

Page 168: ...Temperature Sensor To System Flow Check Close Nipple Locate Header Sensor As Close As Possible To Downstream Tee Hydrolic Separator May Be Substituted For Tees Y Strainer Recommended Cold Water Line Boiler Circulator Optional Full Port Isoltaion Valves At least eight pipe diameters upstream of first tee A No further apart than 12 30 cm or four pipe diameters whichever is smaller B At least 18 46 c...

Page 169: ...assure installation compliance 2 Confirm that all electrical water and gas supplies are shut off at sources 3 Unpack and identify all parts Retain all instructions IX DHW Section on bench 4 Unpack mixing valve and gather three remaining pipe assemblies Identify hot water inlet H cold water inlet C and mixed water outlet connections on mixing valve See Figure C 3 Install copper elbow hot water inle...

Page 170: ...neral piping instructions in the System Piping Section of this manual 16 Installing isolation valves and drain valves on DHW inlet and outlet is recommended to permit flat plate heat exchanger to be flushed periodically 17 Connect to incoming domestic cold water and building domestic hot water systems Refer to Figure C 2 5 Install short pipe to mix end of mixing valve Install flow switch to mixed ...

Page 171: ...g valve temperature setting should be done by a licensed contractor per local code requirements To ensure correct temperature control use the water thermometer at faucet outlet XIV Mixing Valve Set up 23 Set and operate mixing valve per manufacturer instructions If instructions are lost download a new copy from manufacturer s website customer honeywell com before proceeding 24 Measure water temper...

Page 172: ...oper mixing valve operation Annual WARNING Follow boiler shut down procedure in the preceding Sections of this manual before cleaning Flush DHW loop to remove scaling Vinegar can be used to remove scaling Periodic Consult mixing valve manual for maintenance instructions XVII Flat Plate Heat Exchanger Replacement 1 Unscrew control panel assembly from front and tilt back ensuring wire harness connec...

Page 173: ...in the manual open position 3 Remove actuator by depressing locking button and lifting straight up 4 To Install Line up motor coupling to slot in shaft of body and fit the head onto the valve body ensuring it seats correctly 5 Snap actuator onto body by pressing down 6 Wire connection to harness Ensure actuator is set to AUTO mode 7 Inspect the actuator installation and the valve body to ensure it...

Page 174: ...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 175: ...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 176: ...176 106375 01 4 16 U S Boiler Company Inc P O Box 3020 Lancaster PA 17604 1 888 432 8887 www usboiler net ...

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