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U.S. Boiler Company K2 Installation Instructions Manual

Other manuals for K2: Operating Instructions Manual
Manual is about: CONDENSING HIGH EFFICIENCY DIRECT VENT GAS-FIRED HOT WATER BOILER

Summary of K2

  • Page 1

    1 105294-05 - 5/15 price - $5.00 warning: improper installation, adjustment, alteration, service or maintenance can cause property damage, injury, or loss of life. For assistance or additional information, consult a qualified installer, service agency or the gas supplier. This boiler requires a spec...

  • Page 2

    2 105294-05 - 5/15 important information - read carefully note: the equipment shall be installed in accordance with those installation regulations enforced in the area where the installation is to be made. These regulations shall be carefully followed in all cases. Authorities having jurisdiction sh...

  • Page 3

    3 105294-05 - 5/15 warning asphyxiation hazard. This boiler requires regular maintenance and service to operate safely. Follow the instructions contained in this manual. Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. ...

  • Page 4

    4 105294-05 - 5/15 special installation requirements for massachusetts a. For all sidewall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes and where the sidewall exhaust vent termination is less than seven ...

  • Page 5

    5 105294-05 - 5/15 follow all instructions and warnings printed in this manual and posted on the boiler. Maintain the boiler. To keep your boiler safe and efficient, have a service technician maintain this boiler as specified in service and maintenance manual. If you are not qualified to install or ...

  • Page 6

    6 105294-05 - 5/15 i. Product description 7 ii. Specifications 7 iii. Before installing 8 iv. Locating the boiler 9 v. Mounting the boiler 11 vi. Air for ventilation 14 vii. Venting 15 a. Vent system design 15 b. Design requirements unique to horizontal twin pipe venting systems 21 c. Design require...

  • Page 7

    7 105294-05 - 5/15 ii. Specifications figure 2.1: general configuration this boiler is a stainless steel gas fired condensing boiler designed for use in forced hot water heating systems requiring supply water temperatures of 180°f or less. It is designed for installation on a wall. This boiler may b...

  • Page 8

    8 105294-05 - 5/15 table 2.3: vent lengths table 2.2: specifications model* maximum input (mbh) minimum input (mbh) d.O.E. Heating capacity (mbh) ahri net rating * (mbh) water volume (gal.) dim. “a” supply & return connection size (npt) gas connection size (npt) approx. Net weight (lb.) k2-080 80 16...

  • Page 9

    9 105294-05 - 5/15 4. All boilers are shipped from the factory configured for use with natural gas. They may be converted for use with lp gas (“propane”) using a combustion analyzer in accordance with the instructions in appendix a. Danger • do not attempt to operate this boiler on lp gas without co...

  • Page 10

    10 105294-05 - 5/15 figure 4.1: minimum clearances to combustible construction iv. Locating the boiler (continued).

  • Page 11

    11 105294-05 - 5/15 a. Wall mounting 1. If the boiler is installed on a framed wall, minimum acceptable framing is 2 x 4 studs on 16” centers. The boiler mounting holes are on 16” centers for installation between two studs at the standard spacing. In cases where the boiler cannot be centered between...

  • Page 12

    12 105294-05 - 5/15 figure 5.1 wall layout/mounting hole location v. Mounting the boiler (continued).

  • Page 13

    13 105294-05 - 5/15 figure 5.2 boiler mounting bracket installation / boiler wall mounting v. Mounting the boiler (continued).

  • Page 14

    14 105294-05 - 5/15 air for combustion must always be obtained directly from outdoors. See section vii for intake piping. Adequate air for ventilation will be present if the clearances specified in this manual are maintained. If this boiler is installed in a room with other appliances, provide adequ...

  • Page 15

    15 105294-05 - 5/15 vii. Venting a. Vent system design there are three basic ways to vent this boiler: • horizontal (“side wall”) twin pipe venting (figure 7.0a) - vent system exits the building through an outside wall. Combustion air and flue gas are routed between the boiler and the terminal(s) us...

  • Page 16

    16 105294-05 - 5/15 figure 7.0c: split venting vii. Venting a. Vent system design (continued) figure 7.0a: horizontal twin pipe figure 7.0b: vertical twin pipe.

  • Page 17

    17 105294-05 - 5/15 • duravent polypro - ulc s636 listed polypropylene special gas vent system. Use of flex piping is not permitted. • selkirk polyflue - ulc s636 listed polypropylene special gas vent system. • centrotherm innoflue sw - ulc s636 listed polypropylene special gas vent system. Use of f...

  • Page 18

    18 105294-05 - 5/15 4. Minimum vent and air intake lengths - observe the minimum vent lengths shown in tables 7.1, 7.13 and 7.21. 5. Clearances to combustibles - maintain the following clearances from the vent system to combustible construction: • vent - 1/4” (also observe clearances through both co...

  • Page 19

    19 105294-05 - 5/15 vii. Venting a. Vent system design (continued) 7. Supporting pipe - vertical and horizontal sections of pipe must be properly supported. Maximum support spacing is as follows: • support cpvc/pvc horizontally and vertically every 4 feet. • support duravent polypro horizontally nea...

  • Page 20

    20 105294-05 - 5/15 vii. Venting a. Vent system design (continued) figure 7.3: expansion loops for cpvc/pvc pipe figure 7.3b figure 7.3a figure 7.3c figure 7.4: wall penetration clearances for pvc vent pipe.

  • Page 21

    21 105294-05 - 5/15 b. Design requirements unique to horizontal twin pipe venting systems table 7.5 summarizes all horizontal twin pipe vent options. Illustrations of horizontal twin pipe vent systems are shown in figures 7.6 – 7.10. In addition to the requirements in part vii-a, observe the followi...

  • Page 22

    22 105294-05 - 5/15 vent option 1 2 3 4 5 6 7 8 illustrated in figure 7.6, 7.7, 7.8 7.6, 7.7, 7.8 7.9, 7.10 7.9, 7.10 7.9 7.9 7.9 7.9 pipe penetration through structure vent wall wall wall wall wall wall wall wall intake wall wall wall wall wall wall wall wall material vent cpvc/ pvc (note 2) cpvc/ ...

  • Page 23

    23 105294-05 - 5/15 vii. Venting b. Design requirements unique to horizontal twin pipe venting systems (continued) 2. Horizontal vent and air intake terminal location - observe the following limitations on the vent terminal location (also see figure 7.11). When locating a concentric terminal, observ...

  • Page 24

    24 105294-05 - 5/15 figure 7.7: horizontal cpvc/pvc venting with 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 hori...

  • Page 25

    25 105294-05 - 5/15 figure 7.9: duravent polypro, selkirk, polyflue or centrotherm 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 requiremen...

  • Page 26

    26 105294-05 - 5/15 vii. Venting b. Design requirements unique to horizontal twin pipe venting systems (continued) note: air intake termination not shown, refer to venting section in k2 installation instructions supplied with the boiler . Figure 7.1 1: location of v ent t erminal relative to w indow...

  • Page 27

    27 105294-05 - 5/15 vii. Venting c. Design requirements unique to vertical venting systems (continued) figure 7.12: snorkel terminal configuration (cpvc/pvc vent systems only) c. Design requirements unique to vertical venting systems table 7.13a summarizes all vertical twin pipe vent options. Table ...

  • Page 28

    28 105294-05 - 5/15 option 10 11 12 13 14 15 16 17 illustrated in figure 7.15, 717 7.15, 7.17 7.17, 7.18 7.17, 7.18 7.17 7.17 7.17 7.17 pipe penetration through structure vent roof roof roof roof roof roof roof roof intake roof roof roof roof roof roof roof roof material vent cpvc/ pvc (note 2) cpvc...

  • Page 29

    29 105294-05 - 5/15 option 18 19 20 21 illustrated in figure 7.19 7.19 7.20 7.20 pipe penetration through structure vent roof roof roof roof intake roof roof roof roof material vent duravent polypro (rigid/ flex) duravent polypro (rigid/ flex) centrotherm innoflue sw/ flex centrotherm innoflue sw/fl...

  • Page 30

    30 105294-05 - 5/15 vii. Venting c. Design requirements unique to vertical venting systems (continued) terminal option j: diversitech concentric terminal (acceptable for vent options 10 & 11) - this terminal is shown in figure 7.16 and may be used with cpvc/pvc vent systems. See part vii-e of this m...

  • Page 31

    31 105294-05 - 5/15 vii. Venting c. Design requirements unique to vertical venting systems (continued) table 7.14: equivalent length of flex pipe equivalent length (ft) flex vent (1 ft): 2” duravent polypro flex 2.0 ft 2” centrotherm innoflue flex 2.0 ft 2” selkirk polyflue 2.0 ft 3” duravent polypr...

  • Page 32

    32 105294-05 - 5/15 figure 7.15: vertical cpvc/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 (continu...

  • Page 33

    33 105294-05 - 5/15 figure 7.17: duravent polypro, selkirk polyflue or centrotherm 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. Desi...

  • Page 34

    34 105294-05 - 5/15 vii. Venting c. Design requirements unique to vertical venting systems (continued) figure 7.19: duravent polypro b-vent air chase system (vent options #18 & 19) figure 7.20: centrotherm innoflue b-vent air chase system (vent options #20 & 21).

  • Page 35

    35 105294-05 - 5/15 table 7.21 summarizes all split vent options. Illustrations of split vent systems are shown in figures 7.22, 7.23, and 7.24. In addition to the requirements in part vii-a, observe the following design requirements: 1. Permitted terminals for split venting: rigid vent systems (ven...

  • Page 36

    36 105294-05 - 5/15 vii. Venting d. Design requirements unique to split vent systems (continued) example: a 100mbh model is to be installed as using vent option 34 in a masonry chimney as shown in figure 7.23. The following components are used: vent: 3” duravent poly-pro (rigid) – 4ft 3” duravent po...

  • Page 37

    37 105294-05 - 5/15 this page left blank intentionally.

  • Page 38

    38 105294-05 - 5/15 option # 25 26 27 28 29 30 31 32 33 34 35 36 37 38 illustrated in figure 7.22 7.22 7.22 7.22 7.22 7.22 7.22 7.22 7.23, 7.24 7.23, 7.24 7.23, 7.24 7.23, 7.24 7.23, 7.24 7.23, 7.24 pipe penetration through structure vent roof roof roof roof roof roof roof roof roof roof roof roof r...

  • Page 39

    39 105294-05 - 5/15 option # 25 26 27 28 29 30 31 32 33 34 35 36 37 38 illustrated in figure 7.22 7.22 7.22 7.22 7.22 7.22 7.22 7.22 7.23, 7.24 7.23, 7.24 7.23, 7.24 7.23, 7.24 7.23, 7.24 7.23, 7.24 pipe penetration through structure vent roof roof roof roof roof roof roof roof roof roof roof roof r...

  • Page 40

    40 105294-05 - 5/15 vii. Venting d. Design requirements unique to split vent systems (continued) figure 7.22: split rigid vent system (vent options 25-32) figure 7.23: split vent system (flex in b-vent chase) vent options 33-38).

  • Page 41

    41 105294-05 - 5/15 vii. Venting d. Design requirements unique to split vent systems (continued) figure 7.24: split vent system (flex in abandoned masonry chimney) (vent options 33-38).

  • Page 42

    42 105294-05 - 5/15 vii. Venting d. Design requirements unique to split vent systems (continued) venting of other appliances (or fireplace) into chase or adjacent flues prohibited! Figure 7.25: masonry chimney chase requirements.

  • Page 43

    43 105294-05 - 5/15 vii. Venting e. Assembly of cpvc/pvc vent systems (continued) warning asphyxiation hazard. Failure to follow these instructions could cause products of combustion to enter the building, resulting in severe property damage, personal injury or death. Use all cpvc vent components (s...

  • Page 44

    44 105294-05 - 5/15 vii. Venting e. Assembly of cpvc/pvc vent systems (continued) figure 7.27: vent connections and flue gas sample cap location g. Assemble the rest of the vent system, being sure to pitch horizontal sections back towards the boiler 1/4”/ft. Support the vent at intervals not exceedi...

  • Page 45

    45 105294-05 - 5/15 figure 7.29: installation of standard vertical terminals figure 7.28: installation of standard horizontal terminals vii. Venting e. Assembly of cpvc/pvc vent systems (continued).

  • Page 46

    46 105294-05 - 5/15 vii. Venting e. Assembly of cpvc/pvc vent systems (continued) warning asphyxiation hazard. Cpvc/pvc vent piping and fittings rely on glued joints for proper sealing. Follow all manufacturer instructions and warnings when preparing pipe ends for joining and using the primer and th...

  • Page 47

    47 105294-05 - 5/15 figure 7.31: installation of diversitech low profile terminal through sidewall figure 7.30: installation of ipex low profile terminal through sidewall vii. Venting e. Assembly of cpvc/pvc vent systems (continued).

  • Page 48

    48 105294-05 - 5/15 vii. Venting e. Assembly of cpvc/pvc vent systems (continued) figure 7.33: installation of ipex and diversitech concentric terminal through sidewall figure 7.32: cutting ipex and diversitech concentric vent terminals.

  • Page 49

    49 105294-05 - 5/15 figure 7.34: installation of ipex and diversitech concentric terminal through roof vii. Venting e. Assembly of cpvc/pvc vent systems (continued) b. For vertical installations, cut a hole in the roof large enough to clear the concentric terminal at the location of the terminal (se...

  • Page 50

    50 105294-05 - 5/15 figure 7.35: polypro locking band installation vii. Venting f. Assembly of duravent polypro vent systems (continued) f. Assembly of duravent polypro vent systems 1. This boiler has been approved for use with the duravent polypro single wall polypropylene vent system to be provide...

  • Page 51

    51 105294-05 - 5/15 vii. Venting f. Assembly of duravent polypro vent systems (continued) 3. Installation of air intake system - start assembly of the pvc air intake system at the boiler. Assembly of the air intake system is done in the same manner as the vent system except as follows: a. Drill a 7/...

  • Page 52

    52 105294-05 - 5/15 figure 7.36: installation of duravent polypro uv resistant single wall horizontal terminal figure 7.37: installation of duravent polypro uv resistant single wall vertical terminal vii. Venting f. Assembly of duravent polypro vent systems (continued).

  • Page 53

    53 105294-05 - 5/15 vii. Venting f. Assembly of duravent polypro vent systems (continued) 6. Installation of duravent polypro horizontal concentric vent terminal (terminal option d) - install polypro horizontal concentric termination kit #2pps-hk or #3pps-hk (figure 7.39) as follows: a. At the plann...

  • Page 54

    54 105294-05 - 5/15 figure 7.39: installation of duravent polypro concentric vent terminal through sidewall vii. Venting f. Assembly of duravent polypro vent systems (continued) figure 740: installation of duravent polypro concentric terminal through roof.

  • Page 55

    55 105294-05 - 5/15 vii. Venting f. Assy of duravent polypro & g. Selkirk polyflue vent systems (continued) 8. Installations using polypro-flex (vent options 18,19,33,34) : warning asphyxiation hazard. When using polypro flex, observe the following precautions: • polypro flex may be damaged by handl...

  • Page 56

    56 105294-05 - 5/15 vii. Venting g. Assembly of selkirk polyflue vent systems (continued) e. Support each pipe section as described in polyflue manual at intervals not exceeding the following: pipe size horizontal vertical 2” 30in 16ft 3” 39in 16ft notice once a vent pipe is inserted into this adapt...

  • Page 57

    57 105294-05 - 5/15 vii. Venting g. Assembly of selkirk polyflue vent systems (continued) 6. Installations using flexible polyflue (vent options 35,36) : warning asphyxiation hazard. When using polyflue flex, observe the following precautions: • polyflue flex may be damaged by handling at low temper...

  • Page 58

    58 105294-05 - 5/15 vii. Venting g. Assembly of selkirk polyflue vent systems (continued) figure 7.42: installation of selkirk polyflue uv resistant single wall horizontal terminal figure 7.43: installation of selkirk polyflue uv resistant single wall vertical terminal.

  • Page 59

    59 105294-05 - 5/15 vii. Venting h. Assembly of centrotherm innoflue vent systems h. Assembly of centrotherm innoflue vent systems 1. This boiler has been approved for use with the centrotherm innoflue single wall polypropylene vent system to be provided by the installer. Warning asphyxiation hazard...

  • Page 60

    60 105294-05 - 5/15 vii. Venting h. Assembly of centrotherm innoflue vent systems 3. Installation of air intake system - start assembly of the pvc air intake system at the boiler. Assembly of the air intake system is done in the same manner as the vent system except as follows: a. Drill a 7/32” clea...

  • Page 61

    61 105294-05 - 5/15 figure 7.45: installation of centrotherm innoflue uv stabilized single wall horizontal terminal figure 7.46: installation of centrotherm innoflue uv stabilized single wall vertical terminal vii. Venting h. Assembly of centrotherm innoflue vent systems.

  • Page 62

    62 105294-05 - 5/15 vii. Venting h. Assembly of centrotherm innoflue vent systems 6. Installations using innoflue flex (vent options 20,21,37,38): warning asphyxiation hazard. When using innoflue flex, observe the following precautions: • innoflue flex may be damaged by handling at low temperatures....

  • Page 63

    63 105294-05 - 5/15 figure 7.47 : condensate piping arrangement vii. Venting i. Condensate trap and drain line (continued) warning asphyxiation hazard. Failure to install the condensate drain in accordance with the above instructions could cause flue gas to enter the building, resulting in personal ...

  • Page 64

    64 105294-05 - 5/15 j. Removing an existing boiler from a common chimney this section only applies if this boiler is replacing an existing boiler that is being removed from a common chimney. In some cases, when an existing boiler is removed from a common chimney, the common venting system may be too...

  • Page 65

    65 105294-05 - 5/15 gas piping to the boiler must be sized to deliver adequate gas for the boiler to fire at the nameplate input at an inlet pressure between the minimum and maximum values shown in table 8.2. When sizing, also consider other existing and expected future gas utilization equipment (i....

  • Page 66

    66 105294-05 - 5/15 model max. (natural & lp) min. (natural) min. (lp) k2-080 14.0” 2.5” 11.0” k2-100 14.0” 2.5” 11.0” k2-120 14.0” 2.5” 11.0” k2-150 14.0” 2.5” 11.0” k2-180 14.0” 2.5” 11.0” table 8.2: minimum and maximum inlet pressures viii. Gas piping (continued) caution support the weight of the...

  • Page 67

    67 105294-05 - 5/15 ix. System piping a. General system piping precautions warning failure to properly pipe boiler may result in improper operation and damage to boiler or structure. Install boiler so that the gas ignition system components are protected from water (dripping, spraying, rain, etc.) d...

  • Page 68

    68 105294-05 - 5/15 b. Near boiler piping design proper operation of this boiler requires that the water flow rate through it remain within the limits shown in table 9.1 any time the boiler is firing. At flow rates below the minimum shown, the boiler’s flow switch and/or temperature rise limit funct...

  • Page 69

    69 105294-05 - 5/15 figure 9.2: piping method #1 - near boiler piping - heating only ix. System piping (continued).

  • Page 70

    70 105294-05 - 5/15 figure 9.2a: piping method #1 - near boiler piping with k2 fastpipe™ primary/secondary header - heating only primar y/secondar y header inst alla tion 106259-01 - sizes 080 - 120 106259-02 - sizes 150 & 180

  • Page 71

    71 105294-05 - 5/15 figure 9.3a: piping method #1 - near boiler piping - heating plus indirect w ater heater ix. System piping (continued).

  • Page 72

    72 105294-05 - 5/15 ix. System piping (continued) figure 9.3b: piping method #2 - near boiler piping - heating plus indirect w ater heater.

  • Page 73

    73 105294-05 - 5/15 example – a 120mbh model is to be connected to a heating system as shown in figure 9.6. A total of 20 ft of straight pipe will be installed between the boiler and the system loop. Count all fittings in the boiler loop (shaded in figure 9.6): 3 90° elbows 2 turn in tee (under boil...

  • Page 74

    74 105294-05 - 5/15 figure 9.6: piping method #1 - near boiler piping - shaded boiler loop ix. System piping (continued).

  • Page 75

    75 105294-05 - 5/15 method 2: direct connection to heating system (generally not recommended) in some relatively rare cases it may be possible to connect this boiler directly to the heating system as is done with conventional boilers (figure 9.7). If this is done, the flow rate through the boiler wi...

  • Page 76

    76 105294-05 - 5/15 figure 9.8b: grundfos net circulator performance curve note: must use speed hi to achieve the flow requirement shown in table 9.1 figure 9.8a: taco net circulator performance curve ix. System piping (continued) note: these curves show the flow that can be achieved through the boi...

  • Page 77

    77 105294-05 - 5/15 c. Standard piping installation requirements observe the following requirements when installing the boiler piping: 1) relief valve (required) – the relief valve is shipped loose and must be installed in the location shown in figure 9.9, using the side outlet tee and other fitting...

  • Page 78

    78 105294-05 - 5/15 10) drain valve (required) – install the drain valve supplied as shown in figure 9.9. 11) low water cut-off (may be required by local jurisdiction) – protection of this boiler against low water and/or inadequate flow is provided by the ul353 certified flow switch built into the b...

  • Page 79

    79 105294-05 - 5/15 d. Piping for special situations 1) systems containing oxygen - many hydronic systems contain enough dissolved oxygen to cause severe corrosion damage to a this boiler. Some examples include: • radiant systems that employ tubing without an oxygen barrier. • systems with routine a...

  • Page 80

    80 105294-05 - 5/15 figure 10.1 shows the location of both the high voltage and low voltage printed circuit boards with terminal strips for field wiring. To access the pcb’s, first remove the sheet metal screw used to secure the wiring compartment cover and then lift out the cover. 1) line voltage (...

  • Page 81

    81 105294-05 - 5/15 figure 10.1: location of high and low voltage printed circuit boards (pcb) the use of the pump outputs are as follows: a) system pump - pumps water through the radiation. This pump is hydraulically separated from the boiler pump, either by closely spaced tees, or by a hydraulic s...

  • Page 82

    82 105294-05 - 5/15 figure 10.2: high voltage pcb terminal connections figure 10.3: low voltage pcb terminal connections x. Wiring (continued).

  • Page 83

    83 105294-05 - 5/15 • outdoor sensor - tasseron tsa00aa outdoor temperature sensor (1) • outdoor sensor - tasseron tsa00aa outdoor temperature sensor (2) • header sensor - optional honeywell 32003971-003 (103104-01) sensor (1) • header sensor - optional honeywell 32003971-003 (103104-01) sensor (2) ...

  • Page 84

    84 105294-05 - 5/15 figure 10.4: proper installation of header sensor x. Wiring (continued).

  • Page 85

    85 105294-05 - 5/15 x. Wiring (continued) figure 10.5: internal ladder diagram p3‐9 boiler control (r7910b) +v j3‐a j3‐a ‐v j3‐b j3‐b mb1 mb2 rj45 (mb2‐2) panasonic gt02 display sd+ rd+ sd‐ ‐5v +5v rd‐ rj45 (mb2‐1) a ‐v p10‐7 p10‐8 p10‐9 return sensor supply sensor spark j1‐2 j9‐4 j9‐5 j9‐6 wiring l...

  • Page 86

    86 105294-05 - 5/15 x. W iring (continued).

  • Page 87

    87 105294-05 - 5/15 figure 10.6: internal w iring connections diagram x. W iring (continued).

  • Page 88

    88 105294-05 - 5/15 wire no. In fig. 10.5 wire marking wire no. In fig 10.5 wire marking 1 bk p3-10/j4-2 29 bk j2-3/fan-4 2 bk p3-11/j4-4 30 bl j8-4/ret-1 3 bk p3-7/j4-6 31 b/g j8-5/ret-2 4 rd p3-4/j4-3 32 rd j8-8/sup-1 5 wh p3-1/l1a-2 33 r/g j8-9/sup-2 6 rd p3-6/j4-7 34 gy j8-10/sup-3 7 bk p3-9/b1-...

  • Page 89

    89 105294-05 - 5/15 figure 10.8: taco sr504 or equivalent zone panel wiring connection diagram x. Wiring (continued).

  • Page 90

    90 105294-05 - 5/15 x. Wiring (continued) figure 10.9: sage zone control circulator panel wiring connection diagram.

  • Page 91

    91 105294-05 - 5/15 use the following procedure for initial start-up of the boiler: 1) verify that the venting, water piping, gas piping and electrical system are installed properly. 2) confirm all electrical, water and gas supplies are turned off at the source and that vent is clear of obstructions...

  • Page 92

    92 105294-05 - 5/15 xi. Start-up and checkout (continued) danger asphyxiation hazard. Failure to properly convert this boiler for use on lp gas can cause unreliable operation at elevated carbon monoxide (co) levels, resulting in personal injury or death. Notice to minimize the risk of premature heat...

  • Page 93

    93 105294-05 - 5/15 11) start the boiler using the lighting instructions on page 97. With the boiler powered up, and with no call for heat, the display should look like figure 11.2a. Once a call for heat is present, it will look like figure 11.2b. 12) the boiler should attempt to fire approximately ...

  • Page 94

    94 105294-05 - 5/15 figure 11.3: burner flame xi. Start-up and checkout (continued) figure 11.2a: home screen at power-up (no call for heat) figure 11.2b: home screen on heat demand figure 11.2c: home screen with active fault.

  • Page 95

    95 105294-05 - 5/15 xi. Start-up and checkout (continued) warning asphyxiation hazard. Each boiler is tested at the factory and adjustments to the air fuel mixture are normally not necessary when operating on natural gas at sea level. Consult the factory before attempting to make any such adjustment...

  • Page 96

    96 105294-05 - 5/15 16) perform a combustion test. Boilers are equipped with a screw cap in the vent adapter. Be sure to replace this cap when combustion testing is complete. Check co 2 (or o 2 ) and co at both high and low fire. The boiler may be temporarily locked into high or low fire as follows:...

  • Page 97

    97 105294-05 - 5/15 lighting and operating instructions xi. Start-up and checkout (continued).

  • Page 98

    98 105294-05 - 5/15 to convert this boiler for use on lp gas, perform the following steps: 1) if not already done, install the boiler in accordance with this manual, following all instructions in section xi (start-up and check-out) up to step 10. 2) before attempting to start the boiler turn the thr...

  • Page 99

    99 105294-05 - 5/15 model # counter-clockwise turns (from fully closed) k2-080 3-3/4 k2-100 3 k2-120 4 k2-150 2-3/4 k2-180 6-1/2 figure a.1a: gas valve detail (80mbh thru 120mbh) figure a.1b: gas valve detail (150mbh, 180mbh) table a.2: starting number of throttle turns for conversion to lp gas appe...

  • Page 100

    100 105294-05 - 5/15 6) perform a combustion test, sampling flue products from the tap in the front of the vent adaptor. 7) while the burner is at high fire adjust the throttle as needed to obtain the co 2 (or o 2 ) settings shown in the table a.3: • to reduce the co 2 (increase the o 2 ) turn the t...

  • Page 101

    101 105294-05 - 5/15 warning failure to setup the boiler in accordance with these instructions could result in high amount of carbon monoxide to be produced which could result in death, serious injury, and/or reduced component life. Warning if installing k2-080 or k2-180, do not attempt to convert k...

  • Page 102

    102 105294-05 - 5/15 4. If co is greater than > 150 ppm reduce rate via throttle to lower co 2 staying in window. 5. If co does not go below 150 ppm, reduce fan speed 100 rpm at a time until co is less than 6. Be sure to replace the screw cap in the vent adapter when combustion testing is complete. ...

  • Page 103

    103 105294-05 - 5/15 appendix b - (continued) model no. Fuel measured co 2 approximate de-rate per 1000 ft. 2000-4500 ft. 4501-7800 ft. 7801-10,200 ft. Derate/1000 ft. 2000-4500 ft. Derate/1000 ft. 4501-7800 ft. Derate/1000 ft. 7801-10,200 ft. K2-080 ng 8.7-9.2 8.7-9.1 8.7-9.1 0% 0% 0% lp k2-100 ng ...

  • Page 104

    104 105294-05 - 5/15 important the commonwealth of massachusetts requires compliance with regulation 248 cmr 4.00 and 5.00 for installation of side-wall vented gas appliances as follows: (a) for all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure...

  • Page 105

    105 105294-05 - 5/15 1. Detailed instructions for the installation of the venting system design or the venting system components; and 2. A complete parts list for the venting system design or venting system. (d) manufacturer requirements - gas equipment venting system not provided. When the manufact...

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    106 105294-05 - 5/15.

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    107 105294-05 - 5/15.

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    108 105294-05 - 5/15 u.S. Boiler company, inc. P.O. Box 3020 lancaster, pa 17604 1-888-432-8887 www.Usboiler.Net.