Velocity K2WTC-135 Installation, Operating And Service Instructions Download | Manualshive

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107774-02- 4/18

Price - $5.00

TO THE INSTALLER:

Affix these instructions adjacent to boiler.

TO THE CONSUMER:

Retain these instructions for future reference.

9700609

Installation, Operating and Service Instructions for



Condensing



High Efficiency



Direct Vent



Gas-Fired



Water Boiler

K2WTC

Residential

As an ENERGY STAR

®

Partner, U.S. Boiler

Company has determined that the K2WTC Series

meets the ENERGY STAR

®

guidelines for energy

efficiency established by the United States

Environmental Protection Agency (EPA).

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.

Models:
• K2WTC - 135
• K2WTC - 150
• K2WTC - 180

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Summary of Contents for K2WTC-135

Page 1: ...mpany has determined that the K2WTC Series meets the ENERGY STAR guidelines for energy efficiency established by the United States Environmental Protection Agency EPA WARNING Improper installation adj...

Page 2: ...ndicates 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 m...

Page 3: ...ler contains very hot water under high pressure Do not unscrew any pipe fittings nor attempt to disconnect any components of this boiler without positively assuring the water is cool and has no pressu...

Page 4: ...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 b...

Page 5: ...can are hazardous to health and life and that are known to the State of California to cause cancer birth defects and other reproductive harm INSTALL ALL GUARDS cover plates and enclosures before oper...

Page 6: ...ystems 56 H Assembly of Centrotherm InnoFlue Vent Systems 60 I Assembly of Stainless Steel Vent Systems 64 J Condensate Trap and Drain 66 K Removing An Existing Boiler From Common Chimney 67 VIII Gas...

Page 7: ...vented vertically or horizontally with combustion air supplied from outdoors It is not designed for use in gravity hot water systems or systems containing significant amounts of dissolved oxygen I Pro...

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

Page 9: ...d For new radiant heating systems refer to the radiant tubing manufacturer s boiler sizing guidelines For system which includes an indirect water heater make sure the boiler has the output called for...

Page 10: ...10 107774 02 4 18 Figure 4 1 Minimum Clearances To Combustible Construction IV Locating the Boiler continued...

Page 11: ...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 us...

Page 12: ...12 107774 02 4 18 Figure 5 1 Wall Layout Mounting Hole Location V Mounting The Boiler continued...

Page 13: ...13 107774 02 4 18 Figure 5 2 Boiler Mounting Bracket Installation Boiler Wall Mounting V Mounting The Boiler continued...

Page 14: ...g and the bottom edge of the lower opening within 12 of the floor Each of these openings must have a free area of at least 100 square inches The free area takes into account the blocking effect of mes...

Page 15: ...ly 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...

Page 16: ...16 107774 02 4 18 Figure 7 0c Split Venting VII Venting A Vent System Design continued Figure 7 0a Horizontal Twin Pipe Figure 7 0b Vertical Twin Pipe BOILER...

Page 17: ...e first 90 elbow If more elbows are desired the maximum allowable vent length must be reduced by the amount shown in Table 7 1 for each additional elbow used Termination fittings are never counted It...

Page 18: ...inside 3 CPVC coupling d Install remaining venting as described in this manual If using one of the polypropylene or stain less steel vent systems listed described in this manual use a listed adapter t...

Page 19: ...ot Pitch Polypropylene vent piping 5 8 per foot VII Venting A Vent System Design continued Table 7 1B Vent Air Intake Fitting Equivalent Length CPVC PVC Fitting Equivalent Length ft PolyPro Polyflue o...

Page 20: ...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 o...

Page 21: ...21 107774 02 4 18 VII Venting A Vent System Design continued Figure 7 3 Expansion Loops for CPVC PVC Pipe Figure 7 3b Figure 7 3a Figure 7 4 Wall Penetration Clearances for PVC Vent Pipe Figure 7 3c...

Page 22: ...tion B Ipex Low Profile Terminal Acceptable for Vent Option 1 This terminal is shown in Figure 7 7 If the terminal is oriented vertically alternate orientation shown in Fig 7 7 the exhaust opening mus...

Page 23: ...Option A Fittings Vent Coupling w screen Note 3 3PPS 12B or 3PPS 36B w screen 3PF 10UV or 3PF 39UV w screen ISEP03 or ISEP0339 w screen Intake Elbow w screen Note 3 Elbow w screen Elbow w screen Elbo...

Page 24: ...s The bottom of the vent terminal must be at least 3 feet above any forced air inlet located within 10 feet USA Only A clearance of at least 4 feet horizontally must be maintained between the vent ter...

Page 25: ...rements Unique to Horizontal Twin Pipe Venting Systems continued PITCH INTAKE AWAY FROM BOILER IF POSSIBLE BOILER ROOM PVC AIR INTAKE PIPE CPVC VENT PIPE FIRST 30 ELBOW PVC VENT PIPE PITCH VENT PIPE 1...

Page 26: ...Option 2 Terminal Option F VII Venting B Design Requirements Unique to Horizontal Twin Pipe Venting Systems continued PITCH INTAKE AWAY FROM BOILER IF POSSIBLE BOILER ROOM TRIM COLLAR SELKIRK POLYFLUE...

Page 27: ...tal Twin Pipe Venting Systems continued Note Air intake termination not shown Figure 7 11 Location of Vent Terminal Relative to Windows Doors Grades Overhangs Meters and Forced Air Inlets Two Pipe Sys...

Page 28: ...of PolyPro Polyflue or InnoFlue exposed to the outdoors must be UV resistant Use of rodent screens not supplied is generally recommended for both terminations These can be fabricated from 2 x 2 1 2 me...

Page 29: ...n Intake 180 Elbow w Screen 180 Elbow w Screen 180 Elbow w Screen 180 Elbow w Screen Terminal Option I Ipex FGV Concentric Ipex 196006 Note 3 Not Permitted Terminal Option J DiversiTech CVENT Concentr...

Page 30: ...ze of B vent e g 3PPS BV6 is for use with 6 B vent Specify length in feet Specify Flex length and B vent diameter e g IFBK032506 includes 25ft of flex and used with 6 B vent Note 1 Max vent lengths sh...

Page 31: ...outside wall see Section VII D for additional details All venting is Polypropylene supplied by the vent manufacturer shown in Table 7 13b The portion of this venting within the B vent is flexible All...

Page 32: ...lent Length ft Flex Vent 1 ft 3 DuraVent PolyPro Flex 2 0 ft 3 Centrotherm InnoFlue Flex 2 3 ft 3 Selkirk Polyflue 2 3 ft 3 Duravent FasNSeal Flex 1 0 ft B Vent Air Chase 1ft 3 Flex Vent in 6 or large...

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

Page 34: ...entrotherm InnoFlue Vertical Single Wall PP Venting Vent Options 6 8 Terminal Option H Figure 7 18 Duravent PolyPro Vertical Venting with Concentric Terminal Vent Option 6 Terminal Option K VII Ventin...

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

Page 36: ...terminal location also see Figures 7 22 7 23 7 24a and 7 25a The bottom of all terminals must be at least 12 above the normal snow line In no case should they be less than 12 above grade level If pos...

Page 37: ...25a When using one of these options observe the following requirements When a masonry chimney containing multiple flues is used as a chase the flexible stainless vent installation is permitted through...

Page 38: ...pling w Screen 3PPS 12B or 3PPS 36B w Screen 3PF 10UV or 3PF 39UV w Screen ISEP03 or ISEP0339 w Screen Not Permitted Intake 90 Elbow w Screen 90 Elbow w Screen 90 Elbow w Screen 90 Elbow w Screen Flex...

Page 39: ...135ft 135ft 180 135ft 135ft Rigid Vent Terminals Vent Not Permitted Intake Flex Termination Components Masonry Chimney Chase Vent IFCK03 2SVSCKIT03 2SVFLXCN03 Intake 90 Elbow w Screen 90 Elbow w Scre...

Page 40: ...lit Vent Systems continued Figure 7 22 Split Rigid Vent System Vent Options 11 14 Figure 7 23 Split Vent System Flex in B Vent Chase Vent Options 15 17 PVC AIR INTAKE PIPE FIRE STOP LISTED FOR USE WIT...

Page 41: ...oned Masonry Chimney Vent Options 15 17 CLEAN TIGHT UNUSED CHIMNEY BASE SUPPORT AND ELBOW FOR PPs FLEX PIPE EXTERIOR WALL PLATE PVC AIR INTAKE PIPE DURAVENT POLYPRO VENT PIPE OUTSIDE WALL PPs FLEX PVC...

Page 42: ...que to Split Vent Systems continued Figure 7 24b Flexible PP Masonry Chimney Chase Requirements Venting of Other Appliances Or Fireplace into Chase or Adjacent Flues Prohibited WITH CROWN 45 MAX BOILE...

Page 43: ...IBLE LINER EXTERIOR WALL PLATE BOILER FEMALE FLEX ADAPTER MALE FLEX ADAPTER RIGID ELBOW FOR SS FLEX PIPE ALTERNATE VENT PIPING RIGID TEE WITH CONDENSATE DRAIN CAP 12 MIN 10 OR LESS NORMAL SNOW LINE AB...

Page 44: ...0 Multi Purpose Solvent Cement Always use primer on both the pipe and fitting before applying the cement Assemble the pipe in accordance with the instructions on the cans of primer and cement g Assemb...

Page 45: ...n of twin pipe vertical terminals b The coupling is used to secure the rodent screen to the end of the vent pipe c A 180 bend or two 90 elbows are installed on the top of the air intake pipe If two 90...

Page 46: ...46 107774 02 4 18 Figure 7 29 Installation of Standard Vertical Terminals Figure 7 28 Installation of Standard Horizontal Terminals VII Venting E Assembly of CPVC PVC Vent Systems continued...

Page 47: ...of the vent system to this terminal If the vent system is too short to permit this use the IPEX FGV CPVC terminal a For horizontal installations at the planned location cut a round hole in the exteri...

Page 48: ...4 18 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 Syste...

Page 49: ...18 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...

Page 50: ...rain cap and inner pipe in the location shown on Figure 7 32 for the size terminal kit being used and affix screw and nut Do not overtighten A field supplied rodent screen may also be installed on th...

Page 51: ...to be joined as shown in Figure 7 35 Push the male end of the next section of pipe into the bell until it bottoms out then back out 1 4 5 8 to provide room for thermal expansion Push barb on locking...

Page 52: ...r proper orientation of twin pipe horizontal terminals Outer edge of exhaust coupling must be 10 or less from the wall surface Figure 7 9 b Remove the gasket from the end of the integral exhaust coupl...

Page 53: ...nstallation 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...

Page 54: ...level or sloped 1 8 per foot away from the appliance 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 th...

Page 55: ...7 39 Installation of Duravent PolyPro Concentric Vent Terminal Through Sidewall VII Venting F Assembly of DuraVent PolyPro Vent Systems continued Figure 7 40 Installation of Duravent PolyPro Concentr...

Page 56: ...e vent system to be provided by the installer 2 Assemble the vent system starting at the boiler a Theventadaptorhasthreedifferentinsidediameters Themiddleinsidediameteraccepts3 nominalPolyflue Figure...

Page 57: ...0 elbows are installed on the top of the air intake pipe If two 90 elbows are used a rodent screen can be installed between them Figure 7 43 If a 180 bend is used install a rodent screen in the open s...

Page 58: ...manufacturer will also be required for the run from the boiler to the base of the chimney b Polyflue may not be used in air chase applications Figure 7 41 Polyflue Pipe Locking Band Installation WARN...

Page 59: ...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...

Page 60: ...Push the male end of the next section of pipe into the bell until it bottoms out then back out 1 4 to provide room for thermal expansion Push hook on connecting ring over the bell end of the first sec...

Page 61: ...pipe c A 180 bend or two 90 elbows are installed on the top of the air intake pipe If two 90 elbows are used a rodent screen can be installed between them Figure 7 46 If a 180 bend is used install a...

Page 62: ...tallation 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 C...

Page 63: ...the same size at the base of the vent Route the smooth section of InnoFlue Flex 3 through a cap in the base of this Tee Use a Centrotherm IAWP03B wall plate and RTV to seal this penetration Install th...

Page 64: ...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 Flexible stainless steel vent shall be insta...

Page 65: ...ible stainless steel pipe manufacturer installation instructions and boiler installation Operating and Service Instructions the more restrictive instructions shall govern WARNING Asphyxiation Hazard F...

Page 66: ...pose of condensate in accordance with local codes 4 Do not route or terminate the condensate drain line in areas subjected to freezing temperatures 5 If the point of condensate disposal is above the t...

Page 67: ...I Z223 1 VII Venting K Removing an Existing Boiler From a Common Chimney continued Au moment du retrait d une chaudi re existante les mesures suivantes doivent tre prises pour chaque appareil toujours...

Page 68: ...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...

Page 69: ...ailure to do so will make it difficult or impossible to remove burner for servicing CAUTION Support the weight of the gas line piping independently from the boiler gas connection fitting located on th...

Page 70: ...a leak might go undetected consider isolating the boiler from the system with a heat exchanger Make sure that the expansion tank is properly sized and in good condition If it is not the relief valve m...

Page 71: ...tank for an anti freeze system should be at least 1 2 times greater in size 4 FillValve required Eitheramanualorautomaticfillvalvemaybeused butamanualvalveispreferred because it eliminates unmonitore...

Page 72: ...itch in lieu of a low water cut off on water tube boilers In the event that a local jurisdiction insists upon the installation of a low water cut off with this boiler refer to Part XI and the low wate...

Page 73: ...tween 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 strai...

Page 74: ...74 107774 02 4 18 Figure 9 2 Piping Method 1 Near Boiler Piping Heating Only IX System Piping continued...

Page 75: ...ly spaced tees shown in Figure 9 2 When a hydraulic separator is used in place of the tees the 60 ft equivalent length limitation still applies Select a hydraulic separator having 1 or larger boiler c...

Page 76: ...76 107774 02 4 18 Figure 9 5 Piping Method 1 Near Boiler Piping Shaded Boiler Loop IX System Piping continued...

Page 77: ...below the minimum required when only one zone is calling for heat The one advantage to this method is its installation simplicity It may make sense to use this method when the boiler is to be install...

Page 78: ...Curve Taco 0011 0 5 10 15 20 25 30 35 40 0 2 4 6 8 10 12 14 Flow GPM Available Head ft 0 5 10 15 20 25 30 35 0 2 4 6 8 10 Flow GPM Available Head ft Note These curves show the flow that can be achieve...

Page 79: ...igure 9 8 Consult the heat exchanger manufacturer for proper heat exchanger sizing as well as flow and temperature requirements All components on the oxygenated side of the heat exchanger such as the...

Page 80: ...ion using piping the same size as the discharge connection on the valve 4 Hose Bib Valves Recommended These valves permit the DHW plate heat exchanger be periodically back flushed to remove sediment 5...

Page 81: ...81 107774 02 4 18 X Domestic Hot Water Piping continued Figure 10 1 Domestic Hot Water Piping...

Page 82: ...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 res...

Page 83: ...two terminals must be removed Failure to remove this jumper will render the external safety devices ineffective b Outdoor Sensor Use only the Tasseron TSA00AA outdoor sensor supplied with the boiler...

Page 84: ...84 107774 02 4 18 Figure 11 2 Line Voltage Field Connections Figure 11 3 Low Voltage PCB Terminal Connections XI Wiring continued...

Page 85: ...cts ASRSFSRSF16K305B 12 lead between contacts SRSF 21T 250A Recommended for size 20 AWG wire ASRSFSRSF20K51B 2 lead between contacts ASRSFSRSF20K152B 6 lead between contacts ASRSFSRSF20K305B 12 lead b...

Page 86: ...86 107774 02 4 18 Figure 11 4b 24 Volt LWCO Field Wiring Using 24 VAC Transformer XI Wiring continued Figure 11 4a 120 Volt LWCO Field Wiring Figure 11 4c 24 Volt LWCO Field Wiring Using Control ECOM...

Page 87: ...87 107774 02 4 18 Figure 11 6 J3 Field Wiring Figure 11 5 4 20 mA EMS Field Wiring XI Wiring continued...

Page 88: ...J8 9 J8 8 J8 11 J8 5 J10 7 J10 8 Outdoor Temp J6 7 J6 8 Flue Gas Sensor 1 DC 2 Tach 4 PWM 5 DC J2 3 Fan PWM J2 4 DC J2 1 Tach J2 2 DC Combustion Fan DC Conn T1 8 T1 7 Internal non replaceable 2 amp J...

Page 89: ...89 107774 02 4 18 XI Wiring continued...

Page 90: ...90 107774 02 4 18 Figure 11 8 Internal Wiring Connections Diagram XI Wiring continued...

Page 91: ...P3 12 SPL GY 1 14a YE J8 2 SPL Y 1 24a GY SPL GY 1 FLOW 1 14b YE SPL Y 1 P3 2 P3 2 GAS 2 24b GY SPL GY 1 SPS 15 GR J4 12 P3 3 P3 3 IGN GND 25 GY SPS THERM 2 16 RD J5 2 P3 4 P3 4 GAS 1 26 BL J4 3 P5 7...

Page 92: ...92 107774 02 4 18 Figure 11 9 TACO SR504 or Equivalent Zone Panel Wiring Connection Diagram XI Wiring continued...

Page 93: ...93 107774 02 4 18 Figure 11 10 Sage Zone Control Circulator Panel Wiring Connection Diagram XI Wiring continued...

Page 94: ...al before attempting start up 6 Bleed air from the heat exchanger using the manual air vent in the top left side of the heat exchanger Figure 12 1 To do this install a piece of ID clear tubing over th...

Page 95: ...or 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 met...

Page 96: ...nce 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 ignit...

Page 97: ...n Heat Demand Figure 12 2c Home Screen with Active Fault 180 F Energy Save On High Efficiency On Help Adjust Standby Status Detail i kbtu hr 0 Boiler Combi 180 F Energy Save On High Efficiency On Help...

Page 98: ...OGIN e Press 000 f Enter the password 086 g Press return arrow to close the keypad h Press SAVE i Press ADJUST j Press MANUAL CONTROL k Press HIGH or LOW as appropriate WARNING Do not attempt to opera...

Page 99: ...e than 1 8 turns and allow the boiler at least a minute to respond before making another adjustment 17 Perform a check of the ignition safety shut off device With the burner firing carefully unplug th...

Page 100: ...E In some cases such as when the gas valve is replaced the throttle may be far enough out of adjustment that it is not possible to fire the boiler while dialing in the CO2 or O2 using a combustion ana...

Page 101: ...101 107774 02 4 18 Lighting and Operating Instructions XII Start Up and Checkout continued...

Page 102: ...y management system is installed that reduces the boiler water temperature as the heating load decreases This boiler is not used for any space heating This boiler is part of a modular or multiple boil...

Page 103: ...temperature is above the WWSD setpoint this function will shut down the boiler boiler and system pump 8 Energy Management System EMS Interface A factory configured RS485 Modbus interface is available...

Page 104: ...he odds that a micro zone demand can be satisfied using the heat in a buffer tank or elsewhere in the system At the end of the priority time the boiler will divert its entire output to the CH demand a...

Page 105: ...ed position after the blower starts If the air proving switch is not in the required position the start sequence is halted or the boiler is shut down and the open limitindicationisprovided Theairprovi...

Page 106: ...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...

Page 107: ...at Domestic Hot Water Sequencer Control peer to peer Demand or Frost Protection Warm Weather Shutdown status is shown Standby is shown when no demand is present Energy Save On Indication Outdoor Air R...

Page 108: ...F Rate Zone Control Status press for zone cycles Panel 1 1 2 3 4 Panel 2 1 2 3 4 i Status 50 Rate Stack 180 F 180 F Return Supply 180 F i Heat Demand Central Heat ON Auxiliary Heat Off Domestic Hot Wa...

Page 109: ...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 ar...

Page 110: ...e only shown when the Sequence Master is enabled 4 Detail Screens Figure 13 8 Detail Screen Overview Zone Control Status press for zone cycles i Zone Panel 1 Demand Cycles KITCHEN 45 BEDROOMS 20 BASEM...

Page 111: ...e return arrow to close the keypad Press the Save button Press the Adjust button to enter Adjustment mode Figure 13 9 Adjust Mode Screens Login to Access Adjustment Mode For Service Contact CONTRACTOR...

Page 112: ...nsor is not connected to the boiler the sensor is not monitored for faults Wired Outdoor Sensor is installed directly on the boiler terminal Strip Wireless Outdoor sensor is installed and wireless Ena...

Page 113: ...Heat Rate This parameter defines the highest modulation rate the Control will go to during the auxiliary heat call for heat If the rated input of the Auxiliary Heat Zones is less than the maximum out...

Page 114: ...Light off Rate RPM 4000 4000 Model K2WTC 135B 26 P K2WTC 150B 26 P Maximum Firing Rate CH DHW RPM 8500 8700 Minimum Firing Rate RPM 1800 1900 Default Light off Rate RPM 4000 4000 Altitude 6001 7800ft...

Page 115: ...reens HeatMatch Software Example call for heat durations for a four zone house Maximum heat rate limits firing rate and prevents the Control from firing to 100 in response to a smaller zone demands Ma...

Page 116: ...according to selected function Central Heat No Priority Pump Runs during central heat auxiliary heat and frost protection call for heat Pump does not start for a DHW call for heat but will run during...

Page 117: ...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 Phon...

Page 118: ...w degrees below the setpoint 3 1 to 5 Response Speed This parameter adjusts the Central Heat temperature controller Proportion Integral Derivative PID values Higher values cause a larger firing rate c...

Page 119: ...elow the setpoint 3 1 to 5 Response Speed This parameter adjusts the Auxiliary Heat temperature controller Proportion Integral Derivative PID values Higher values cause a larger firing rate change for...

Page 120: ...omestic hot water demand will have priority for the duration of this Priority time At the end of that time the boiler will respond to the call for space heat and no domestic hot water will be availabl...

Page 121: ...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...

Page 122: ...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...

Page 123: ...Setpoint Heating Element Type 180 F to 190 F 82 2 C to 87 8 C Fan Coil 100 F to 140 F 37 8 C to 60 C In Slab Radiant High Mass Radiant 160 F to 190 F 71 1 C to 87 8 C Convection Baseboard Fin Tube Co...

Page 124: ...Modbus Address when a Energy Management System is connected Normal Use Boiler First Normal Use Boiler Last Slave Selection Order Use Boiler First places the Slave in the lead permanently Normal firing...

Page 125: ...respirator 2 Long sleeved loose fitting clothing 3 Gloves 4 Eye Protection Take steps to assure adequate ventilation Wash all exposed body areas gently with soap and water after contact Wash work clot...

Page 126: ...pass any safety or operating control or component of this boiler Assure that all safety and operating controls and components are operating properly before placing the boiler back in service Annually...

Page 127: ...ached securely d Verify that the gas shutoff shown in Figure 8 1 is closed e Disconnect the union under the boiler Figure 8 1 f Unplug the electrical connection to the gas valve g Disconnect the air p...

Page 128: ...128 107774 02 4 18 Figure 14 1 Flame Ionization Electrode and Ignition Electrode Location XIV Service and Maintenance continued...

Page 129: ...ndensate cleanout cap on the bottom of the boiler see Figure 2 1 to catch water in the trap as well as the ball and ball support Unscrew the cap being careful not to lose the ball or ball support Flus...

Page 130: ...arts View CONDENSATE HOSE FROM HEAT EXCHANGER CONDENSATE TRAP VENT TUBING CONDENSATE TRAP CABINET COMPONENTS OMITTED FOR CLARITY I BALL FLOAT 0 I FLOAT SUPPORT GASKET I FLOAT SUPPORT 1 mf O RING FOR C...

Page 131: ...on boiler water and the use of boiler water additives u Test the boiler flow switch To do this Start with the boiler in standby Either close a shut off in the boiler loop or unplug the boiler pump at...

Page 132: ...shortened but this may cause a lack of hot water at fixtures during long DHW draws No hot water at fixtures Boiler not responding to call for DHW Status and Priority show Standby Boiler is not seeing...

Page 133: ...n light is connected to internal power supply The power supply is repeatedly starting and stopping not normal making the light flash The microprocessors are not running Try disconnecting all terminals...

Page 134: ...d 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 si...

Page 135: ...ed 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...

Page 136: ...osed 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 t...

Page 137: ...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...

Page 138: ...ower 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...

Page 139: ...30 8056 104 40 5324 122 50 3599 140 60 2483 158 70 1748 176 80 1252 194 90 912 212 100 674 230 110 506 248 120 384 Table 15 3b Outdoor Air Temperature Sensor Temperature versus Resistance Outdoor Tem...

Page 140: ...028 50 10 0 22804 55 12 8 20301 60 15 6 17906 65 18 3 15948 68 20 0 14773 70 21 1 14157 75 23 9 12616 77 25 0 12000 80 26 7 11268 85 29 4 10048 86 30 0 9804 90 32 2 9026 95 35 0 8054 100 37 8 7275 104...

Page 141: ...Number 135 150 180 1 Fixing Clamp Bracket Contact U S Boiler Company Provide boiler serial number 2 Holding Clamp 3 M4 x 7 Fixing Clamp Screw 4 10 32 x 1 2 Thread Cutting Screw 5 Bare Heat Exchanger...

Page 142: ...142 107774 02 4 18 XVI Repair Parts continued...

Page 143: ...Sensor 105910 01 21 17 17A 22 Piping Block Kit 108209 01 108210 01 23 27 Supply Pipe Repair Kit includes supply piping assembly and locknut 108212 01 24 Supply Temperature Sensor 105911 01 25 T P Gau...

Page 144: ...4 18 XVI Repair Parts continued Key No Description Part Number 135 150 180 40 43 27 46 47 DHW Fitting Set 108197 01 41 41A DHW Flow Switch 108155 01 42 44 DHW CSST Set 108196 01 45 DHW Temperature Sen...

Page 145: ...145 107774 02 4 18 XVI Repair Parts continued...

Page 146: ...Gas Conversion Kit excludes M models 107874 01 107875 01 48 49 50 Blower Outlet Gasket 106029 01 51 52 Gas Line Seal includes gas line escutcheon plate gasket and hardware 107898 01 53 Air Proving Pre...

Page 147: ...cription Part Number 135 150 180 62 63 64 Condensate Trap includes gasket bracket and trap ball 105851 01 65 Ball for Condensate Trap 105850 01 66 Trap Harness Kit 107159 01 54 67 68 69 70 71 73 Tubin...

Page 148: ...148 107774 02 4 18 XVI Repair Parts continued...

Page 149: ...Gasket Replacement Kit 108188 01 78 Transformer 106034 01 81 Ignition Cable 107152 01 82 Boiler Control 2 3 107877 01 84 85 86 87 88 89 120 121 J Box Replacement Kit 108207 01 90 91 Low Voltage Print...

Page 150: ...150 107774 02 4 18 XVI Repair Parts continued...

Page 151: ...gaskets 108216 01 108217 01 99 K2WTC Replacement Door 108202 01 101 102 Intake Repair Kit 105848 01 103 104 Vent Connector includes connector gasket and hardware 107034 01 106 107 108 109 110 Front D...

Page 152: ...152 107774 02 4 18 XVI Repair Parts continued 120 121 122 123 124 125 126 127...

Page 153: ...122 Internal DC Harness 108206 01 123 Internal AC Harness 108205 01 124 Circ Zone Valve Harness 3 req d per boiler 108192 01 125 Control Box Harness 108195 01 126 Display Harness 108199 01 127 Combi...

Page 154: ...so may result in unreliable operation property damage personal injury or loss of life due to carbon monoxide CO poisoning WARNING LP Conversions K2WTC boiler setup from factory is configured for use...

Page 155: ...itted LP Low Fire Range and Target values are the same as High Fire above Ensure low fire CO2 reading is less than or equal to high fire CO2 reading Model No Fuel Measured O2 Max Co Air Free 2001 6000...

Page 156: ...80 15 14 Appendix A continued Model No Fuel Approximate Derate per 1000 ft 2001 6000 ft 6001 7800 ft 7801 10 100 ft K2WTC 135B NG 1 2 1 8 2 4 LP 1 7 3 3 Not Permitted K2WTC 150B NG 2 6 2 9 3 1 LP 3 2...

Page 157: ...lled on the next adjacent floor level b In the event that the requirements of this subdivision can not be met at the time of completion of installation the owner shall have a period of thirty 30 days...

Page 158: ...ct Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases but identifies special venting systems the following requirements shall be satisfie...

Page 159: ...159 107774 02 4 18 SERVICE RECORD DATE SERVICE PERFORMED...

Page 160: ...160 107774 02 4 18 U S Boiler Company Inc P O Box 3020 Lancaster PA 17604 1 888 432 8887 www usboiler net...

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