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

Condensing high efficiency direct vent gas - fired hot water boiler
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INSTALLATION, OPERATING AND
SERVICE INSTRUCTIONS FOR
CONDENSING HIGH EFFICIENCY
GAS - FIRED HOT WATER BOILER
9700609
Space Heating Models:
• K2FT-085
• K2FT-110
• K2FT-155
• K2FT-205
• K2FT-270
Combi Domestic Hot Water
and Space Heating Model:
• K2FTC-155
As an ENERGY STAR
STAR
guidelines for energy efficiency established by the United States Environmental Protection Agency (EPA).
®
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.
106375-01 - 4/16
K2FT™
DIRECT VENT
Partner, U.S. Boiler Company has determined that the K2FT™ Series meets the ENERGY
®
WARNING
Price - $5.00
1

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Summary of Contents for U.S. Boiler Company K2FT-085

  • Page 1 Combi Domestic Hot Water and Space Heating Model: • K2FTC-155 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).
  • Page 2 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 shall be consulted before installations are made.
  • Page 3 WARNING Asphyxiation Hazard. Fire Hazard. Explosion Hazard. This boiler requires regular maintenance and service to operate safely. Follow the instructions contained in this manual. 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 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 (7) ft. above grade, the following requirements shall be satisfied: 1.
  • Page 5 WARNINGS FOR THE HOMEOWNER FOLLOW ALL INSTRUCTIONS and warnings unless alarms or other safeguards are in place to printed in this manual and posted on the boiler. prevent such damage. MAINTAIN THE BOILER. To keep your boiler safe DO NOT BLOCK AIR FLOW into or around the and efficient, have a service technician maintain boiler.

  • Page 6: Table Of Contents

    Table of Contents Product Description Specifications III. Before Installing Locating The Boiler Mounting The Boiler Air For Ventilation VII. Venting A. Vent System Design Design Requirements Unique to Horizontal Twin Pipe Venting Systems Design Requirements Unique to Vertical Venting Systems D.

  • Page 7: I. Product Description

    It is not designed for use in gravity hot water systems or systems containing significant amounts of dissolved oxygen. Models K2FT-085 through 270 provide central space 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.
  • Page 8 II. Specifications (continued) Combustion Air Blower Gas Valve Air Proving Switch Flue/Inlet Switch Manual Gas Programmed Shutoff Valve Display Transformer Supply Sensor Flue Temperature Return Sensor Sensor 24 V Fuse High Voltage Fuse High Voltage Low Voltage Front Door and Front Door Removed Control Panel Removed...

  • Page 9: Iii. Before Installing

    II. Specifications (continued) Table 2.4: Vent Lengths Nominal Approx. Model Min Vent Length Max Vent Vent/Intake Size Derate at Max Vent Size (in) Length (ft) (in) 11.3 See Section VII “Venting” for additional requirements and details. III. Before Installing 1. Safe, reliable operation of this boiler depends upon installation by a professional heating contractor in strict accordance with this manual and the requirements of the authority having jurisdiction.

  • Page 10: Iv. Locating The Boiler

    III. Before Installing (continued) DANGER • Do not attempt to operate this boiler on LP gas without converting it in accordance with the instructions shown in Appendix A. • Do not attempt to convert this boiler to LP gas without the use of a combustion analyzer. •...
  • Page 11 IV. Locating the Boiler (continued) " SERVICE ACCESS PANEL PROVIDE ACCESS TO THIS AREA FRONT VIEW 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. Figure 4.1: Minimum Clearances To Combustible Construction 106375-01 - 4/16...

  • Page 12: V. Mounting The Boiler

    V. Mounting The Boiler A. Wall Mounting CAUTION • Two people are required to safely lift this boiler onto the wall mounting hook. • Make sure that wall mounting hook is anchored to a structure capable of supporting the weight of the boiler and attached piping when filled with water. Jurisdictions in areas subject to earthquakes may have special requirements for supporting this boiler.
  • Page 13 V. Mounting The Boiler (continued) Figure 5.1 Wall Layout / Mounting Hole Location 106375-01 - 4/16...
  • Page 14 V. Mounting The Boiler (continued) Figure 5.2 Boiler Mounting Bracket Installation / Boiler Wall Mounting 106375-01 - 4/16...

  • Page 15: Vi. Air For Ventilation

    VI . Air for Ventilation WARNING Outdoor combustion air must be piped to the air intake. Never pipe combustion air from areas containing contaminates such as swimming pools and laundry room exhaust vents. Contaminated combustion air will damage the boiler and may cause property damage, personal injury or loss of life. Air for combustion must always be obtained directly from outdoors.

  • Page 16: Vii. Venting

    VII. Venting 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.
  • Page 17 VII. Venting A. Vent System Design (continued) Figure 7.0a: Horizontal Twin Pipe Figure 7.0b: Vertical Twin Pipe Figure 7.0c: Split Venting 106375-01 - 4/16...
  • Page 18 VII. Venting A. Vent System Design (continued) 1. Listed Vent Systems and Materials – The following materials and vent systems may be used to vent this boiler: • CPVC – Use only CPVC listed to ASTM F441. In Canada, this pipe must also be listed to ULC S636. •...
  • Page 19 VII. Venting A. Vent System Design (continued) 3. Minimum Vent and Air Intake Lengths - Observe the minimum vent lengths shown in Tables 7.5, 7.13 and 7.21. Clearances to Combustibles - Maintain the following clearances from the vent system to combustible construction: •...
  • Page 20 VII. Venting A. Vent System Design (continued) 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 near the female end of each straight section of pipe and vertically every 10 feet. •...
  • Page 21 VII. Venting A. Vent System Design (continued) Figure 7.3a Figure 7.3b Figure 7.3c Figure 7.3: Expansion Loops for CPVC/PVC Pipe Figure 7.4: Wall Penetration Clearances for PVC Vent Pipe 106375-01 - 4/16...

  • Page 22: B. Design Requirements Unique To Horizontal Twin Pipe Venting Systems

    VII. Venting B. Design Requirements Unique to Horizontal Twin Pipe Venting Systems (continued) 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 –...
  • Page 23 VII. Venting B. Design Requirements Unique to Horizontal Twin Pipe Venting Systems (continued) Table 7.5: Summary of Horizontal Twin Pipe Venting Options Vent Option 7.6, 7.7, 7.6, 7.7, Illustrated in Figure 7.9, 7.10 7.9, 7.10 Pipe Vent Wall Wall Wall Wall Wall Wall...
  • Page 24 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, observe the limitations outlined below for “vent terminals”. •...
  • Page 25 VII. Venting B. Design Requirements Unique to Horizontal Twin Pipe Venting Systems (continued) 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 &...
  • Page 26 VII. Venting B. Design Requirements Unique to Horizontal Twin Pipe Venting Systems (continued) 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 &...
  • Page 27 VII. Venting B. Design Requirements Unique to Horizontal Twin Pipe Venting Systems (continued) 106375-01 - 4/16...

  • Page 28: C. Design Requirements Unique To Vertical Venting Systems

    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 7.13.b summarizes vent options in which an abandoned B-vent chimney is used both as a chase for the vent pipe and as a conduit for combustion air.
  • Page 29 VII. Venting C. Design Requirements Unique to Vertical Venting Systems (continued) Table 7.13a: Summary of Vertical Twin Pipe Venting Options Option 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 Vent Roof Roof Roof Roof Roof...
  • Page 30 VII. Venting C. Design Requirements Unique to Vertical Venting Systems (continued) Table 7.13b: Summary of Vertical “B-Vent Air Chase” Vent Options (B-Vent Chase MUST Be Sealed) Option Illustrated in Figure 7.19 7.19 7.20 7.20 Vent Roof Roof Roof Roof Pipe Penetration Through Structure Intake Roof...
  • Page 31 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 manual and the Diversitech instructions provided with the terminal, for installation details.
  • Page 32 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"...
  • Page 33 VII. Venting C. Design Requirements Unique to Vertical Venting Systems (continued) 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) 106375-01 - 4/16...
  • Page 34 VII. Venting C. Design Requirements Unique to Vertical Venting Systems (continued) 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 &...
  • Page 35 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) 106375-01 - 4/16...

  • Page 36: D. Design Requirements Unique To Split Vent Systems

    VII. Venting D. Design Requirements Unique to Split Vent Systems (continued) D. Design Requirements Unique to Split Vent Systems 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.
  • Page 37 VII. Venting D. Design Requirements Unique to Split Vent Systems (continued) Example: A 110MBH 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"...
  • Page 38 VII. Venting D. Design Requirements Unique to Split Vent Systems (continued) Table 7.21: Summary of Split Vent System Options Option # Illustrated in Figure 7.22 7.22 7.22 7.22 7.22 7.22 Vent Roof Roof Roof Roof Roof Roof Pipe Penetration Through Structure Intake Wall Wall...
  • Page 39 VII. Venting D. Design Requirements Unique to Split Vent Systems (continued) Table 7.21: Summary of Split Vent System Options (continued) 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 Roof Roof Roof Roof Roof Roof Roof Roof Wall...
  • Page 40 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) 106375-01 - 4/16...
  • Page 41 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) 106375-01 - 4/16...
  • Page 42 VII. Venting D. Design Requirements Unique to Split Vent Systems (continued) DANGER Venting of Other Appliances (Or Fire- place) into Chase or Adjacent Flues Prohibited! Figure 7.25: Masonry Chimney Chase Requirements 106375-01 - 4/16...

  • Page 43: E. Assembly Of Cpvc/Pvc Vent Systems

    VII. Venting E. Assembly of CPVC/PVC Vent Systems (continued) E. Assembly of CPVC/PVC Vent Systems DANGER Failure to follow this warning could result in asphyxiation and/or carbon monoxide poisoning. Correct venting material and installation is required for proper vent operation. PVC Vent Systems must include at least 30 inches of CPVC and one CPVC elbow between the boiler and PVC vent piping.
  • Page 44 VII. Venting E. Assembly of CPVC/PVC Vent Systems (continued) Figure 7.26: Vent Connections and Flue Gas Sample Cap Location h. Maintain the clearances from the vent pipe outlined in Part VII-A of this manual. If exiting the exterior wall using PVC pipe, use half of an appropriately sized wall thimble (or a sheet metal plate) on the exterior of the building, to provide a weather tight seal while maintaining the proper clearance in the wall penetration.
  • Page 45 VII. Venting E. Assembly of CPVC/PVC Vent Systems (continued) Figure 7.27: Installation of Standard Horizontal Terminals Figure 7.28: Installation of Standard Vertical Terminals 106375-01 - 4/16...
  • Page 46 VII. Venting E. Assembly of CPVC/PVC Vent Systems (continued) 4. Installation of Vertical Fitting Terminals (Terminal Option H): a. See Figure 7.28 for the proper orientation of twin pipe vertical terminals. b. The coupling is used to secure the rodent screen to the end of the vent pipe. c.
  • Page 47 VII. Venting E. Assembly of CPVC/PVC Vent Systems (continued) Figure 7.29: Installation of IPEX Low Profile Terminal Through Sidewall Figure 7.30: Installation of Diversitech Low Profile Terminal Through Sidewall 106375-01 - 4/16...
  • Page 48 VII. Venting E. Assembly of CPVC/PVC Vent Systems (continued) Figure 7.31: Cutting IPEX and Diversitech Concentric Vent Terminals Figure 7.32: Installation of IPEX and Diversitech Concentric Terminal through Sidewall 106375-01 - 4/16...
  • Page 49 VII. Venting E. Assembly of CPVC/PVC Vent Systems (continued) Figure 7.33: Installation of IPEX and Diversitech Concentric Terminal Through Roof b. For vertical installations, cut a hole in the roof large enough to clear the concentric terminal at the location of the terminal (see Part VII-C of this manual for permitted terminal locations).

  • Page 50: F. Assembly Of Duravent Polypro Vent Systems

    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 provided by the installer. WARNING Asphyxiation Hazard.
  • Page 51 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.
  • Page 52 VII. Venting F. Assembly of DuraVent PolyPro Vent Systems (continued) Figure 7.35: Installation of Duravent PolyPro UV Resistant Single Wall Horizontal Terminal Figure 7.36: Installation of Duravent PolyPro UV Resistant Single Wall Vertical Terminal 106375-01 - 4/16...
  • Page 53 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 7.38) as follows: a. At the planned location cut a 4-1/8" round hole for the 2" terminal or a 5-1/8" round hole for the 3" terminal in the exterior wall.
  • Page 54 VII. Venting F. Assembly of DuraVent PolyPro Vent Systems (continued) Figure 7.38: Installation of Duravent PolyPro Concentric Vent Terminal Through Sidewall Figure 7.39: Installation of Duravent PolyPro Concentric Terminal Through Roof 106375-01 - 4/16...

  • Page 55: G. Assembly Of Selkirk Polyflue Vent Systems

    VII. Venting F. Assembly of DuraVent PolyPro Vent Systems (continued) 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 handling at low temperatures. Do not bend, uncoil, or attempt to install if it has been stored at a temperature below 42°F without allowing it to warm to a higher temperature first.
  • Page 56 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 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.
  • Page 57 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 temperatures. Do not bend, uncoil or attempt to install if it has been stored at a temperature below 42°F without allowing it to warm to a higher temperature first.
  • Page 58 VII. Venting 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 106375-01 - 4/16...

  • Page 59: H. Assembly Of Centrotherm Innoflue Vent Systems

    VII. Venting 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. Follow these instructions and the installation instructions included by the original PolyPropylene venting component manufacturers, Centrotherm.
  • Page 60 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.
  • Page 61 VII. Venting H. Assembly of Centrotherm InnoFlue Vent Systems Figure 7.44: Installation of Centrotherm InnoFlue UV Stabilized Single Wall Horizontal Terminal Figure 7.45: Installation of Centrotherm InnoFlue UV Stabilized Single Wall Vertical Terminal 106375-01 - 4/16...

  • Page 62: I. Condensate Trap And Drain

    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. Do not bend, uncoil or attempt to install if it has been stored at a temperature below 42°F without allowing it to warm to a higher temperature first.
  • Page 63 VII. Venting I. Condensate Trap and Drain Line (continued) 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 boiler.
  • Page 64 VII. Venting J. Removing an Existing Boiler From a Common Chimney (continued) 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 large for the remaining appliances.

  • Page 65: Viii. Gas Piping

    VIII. Gas Piping WARNING Explosion Hazard. Failure to properly pipe gas supply to boiler may result in improper operation or leaks of flammable gas. Gas supply to boiler and system must be absolutely shut off prior to installing or servicing boiler gas piping. Always assure gas piping is absolutely leak free and of the proper size and type for the connected load.
  • Page 66 VIII. Gas Piping (continued) CAUTION Support the weight of the gas line piping independently from the boiler gas connection fitting located on the bottom of the boiler. If an additional regulator is used to reduce boiler inlet pressure below 1/2 psig (3.4 kPa) it must be at least 6 to 10 ft.

  • Page 67: Ix. System Piping

    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.) during boiler operation and service (circulator replacement, etc.).

  • Page 68: B. Standard Piping Installation Requirements

    IX. System Piping (continued) B. 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 9.1. ASME Section IV currently requires that this relief valve be installed above the heat exchanger as shown.
  • Page 69 IX. System Piping (continued) CAUTION Do not reverse supply/inlet and return/outlet piping. Reverse piping will cause premature heat exchanger failure. Positively assure supply/inlet and return/outlet pipes are properly connected as shown in this manual. NOTICE For combi model K2FTC-155, only the inlet bottom/outlet bottom piping configuration may be used. Refer to Appendix C for combi piping.

  • Page 70: C. Near Boiler Piping Design

    IX. System Piping (continued) Remove Plug To Install Optional Low Water Cutoff Figure 9.2: LWCO Location C. Near Boiler Piping Design Proper operation of this boiler requires that the water flow rate through it remain within the limits shown in Table 9.3 any time the boiler is firing.
  • Page 71 IX. System Piping (continued) Method 1: Primary/Secondary Piping (Strongly Recommended) This method can be used in heat-only applications as shown in Figure 9.7a or 9.8a or with an indirect water heater as shown in Figure 9.7b, 9.7c, 9.8b, 9.8c. In this system, the flow rate through the boiler (“secondary loop”) is completely independent of the flow rate through the system (“primary loop”).
  • Page 72 106375-01 - 4/16...
  • Page 73 IX. System Piping (continued) 3) Indirect Water Heater Loop Piping – If an indirect water heater is used, install it as shown in Figure 9.7b, 9.7c, 9.8b, 9.8c. Refer to the indirect water heater installation manual for the proper sizing the indirect water heater loop pump and piping. 4) Hydraulic Separators –...
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  • Page 80 IX. System Piping (continued) Method 2: Direct Connection to Heating System (Generally NOT Recommended) In some cases it may be possible to connect this boiler directly to the heating system as is done with conventional boilers (Figure 9.9). If this is done, the flow rate through the boiler will equal the flow rate through the system. The flow rate through the system must therefore always remain within the limits shown in Table 9.3.

  • Page 81: D. Piping For Special Situations

    IX. System Piping (continued) 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. •...

  • Page 82: X. Wiring

    X. Wiring DANGER Electrical Shock Hazard. Positively assure all electrical connections are unpowered before attempting installation or service of electrical components or connections of the boiler or building. Lock out all electrical boxes with padlock once power is turned off. WARNING All wiring and grounding must be done in accordance with the authority having jurisdiction or, in the absence of such requirements, with the National Electrical Code /NFPA 70).
  • Page 83 X. Wiring (continued) 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 separator. The system pump is always on when the system is responding to a call for CH.
  • Page 84 X. Wiring (continued) 120 VAC Connections Pump Fuse Spare Pump Fuse System Boiler 120 V Line Pump Pump Pump OVERCURRENT PROTECTION/ DISCONNECT (BY INSTALLER) 120VAC/60HZ BOILER SYSTEM POWER PUMP PUMP PUMP SUPPLY Figure 10.2: High Voltage PCB Terminal Connections Low Voltage Connections Fuse F1 250 V 1.6A Slow-Blow 5x20mm MODBUS EnviraCOM...
  • Page 85 X. Wiring (continued) With the exception of the alarm contacts, external power must not be applied to any of the low voltage terminals - doing so may damage the boiler control. Also note the following: a) External Limit - The external limit terminals are intended for use with a field supplied safety device, such as a manual reset high limit.
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  • Page 87 X. Wiring (continued) Figure 10.5: Internal Wiring Ladder Diagram 106375-01 - 4/16...
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  • Page 90 X. Wiring (continued) HEATING THERMOSTATS PRIORITY OFF ZONE 4 TACO SR504 PRIORITY (OR EQUIVALENT) ZONE 1 ZONE 2 ZONE 3 ZONE 4 FOUR ZONE SWITCHING RELAY WITH OPTIONAL PRIORITY POWER ZONE 1 ZONE 2 24 VAC ZONE 3 POWER 120V RELAY ZONE 4 ZONE 1 ZONE 2...
  • Page 91 X. Wiring (continued) HEATING THERMOSTATS RJ45 CONNECTOR END SWITCH 24 VAC THERMOSTATS PRIORITY SLAVE MASTER MAIN PRIORITY EXPANSION ZONE 1 ZONE 2 ZONE 3 ZONE 4 PRIORITY ON RESET NORMAL PRIMARY PUMP ON POST PURGE ON PRIOR. PROTECT ON ZONE CONTROL INDICATORS PUMP EXERCISE ON POWER...

  • Page 92: Xi. Start-Up And Checkout

    XI. Start-Up and Checkout WARNING Completely read, understand and follow all instructions in this manual before attempting start-up. NOTICE Safe lighting and other performance criteria were met with the gas train assembly provided on the boiler when the boiler underwent the test specified in ANSI Z21.13. Use the following procedure for initial start-up of the boiler: Verify that the venting, water piping, gas piping and electrical system are installed properly.
  • Page 93 XI. Start-Up and Checkout (continued) DANGER Asphyxiation Hazard. Failure to properly convert this boiler for use on LP Gas (propane) can cause unreliable operation at elevated carbon monoxide (CO) levels, resulting in personal injury or death. NOTICE To minimize the risk of premature heat exchanger failure, observe the following water chemistry requirements: 1) Minimize the introduction of make-up water, dissolved oxygen, and contaminants into the boiler by following the installation guidelines shown in the “Water Quality and Boiler Water Additives Note”...
  • Page 94 XI. Start-Up and Checkout (continued) 11) Start the boiler using the operating instructions on page 98. With the boiler powered up, and with no call for heat, the display should look like Figure 11.1a. Once a call for heat is present, it will look like Figure 11.1b. 12) The boiler should attempt to fire approximately 30 seconds after a call for heat appears.
  • Page 95 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 Figure 11.2: Burner Flame 106375-01 - 4/16...
  • Page 96 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 adjustments.
  • Page 97 XI. Start-Up and Checkout (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. Table 11.4: Acceptable Combustion Readings for Natural Gas (0-4,500 ft.) Model Max.
  • Page 98 XI. Start-Up and Checkout (continued) Operating Instructions 106375-01 - 4/16...

  • Page 99: Xii. Operation

    XII. Operation IMPORTANT This boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases. This feature is equipped with an override which is provided primarily to permit the use of an external energy management system that serves the same function. THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE: •...
  • Page 100 XII. Operation (continued) 7. Warm Weather Shutdown (WWSD) Table 12.1: Order of Priority Some boilers are used primarily for heating buildings, Status Screen Priority Boiler Responding to: and the boilers can be automatically shutdown when Display the outdoor air temperature is warm. When outside air Sequencer The boiler is connected to the peer- temperature is above the WWSD setpoint, this function...
  • Page 101 XII. Operation (continued) 5. Outdoor Air Reset C. Boiler Protection Features If an outdoor temperature sensor is connected to 1. Supply Water Temperature High Limit the boiler and Outdoor Reset is enabled, the Central The control is equipped with internal operating Heat setpoint will automatically adjust downwards as control and high limit features.
  • Page 102 XII. Operation (continued) D. Multiple Boiler Control Sequencer 5. Boiler Mounted Limit Devices The control monitors individual limit devices: External 1. “Plug & Play” Multiple Boiler Control Limit, Optional Low Water Cut-Off (LWCO) and Sequencer Blocked Flue/Inlet Switch. If any of these limits open When multiple boilers are installed, the Control’s the boiler will shut down and an open limit indication Sequencer may be used to coordinate and optimize...
  • Page 103 XII. Operation (continued) 10. Innovative Condensing Boiler Control 5. Customized Sequences During low loads, the Sequence Master limits firing rates Normally, boilers are started and stopped in numerical to a “Base Load Common Rate” to ensure modulating order. However, custom sequences may be established condensing boiler peak operating efficiency.

  • Page 104: Normal Operation

    XII. Operation (continued) E. Boiler Sequence of Operation 1. Normal Operation Table 12.3: Boiler Sequence of Operation Status Screen Display Description Priority: (burner Off, circulator(s) Off) Standby Boiler is not firing and there is no call for heat, priority equals standby. The boiler Status: is ready to respond to a call for heat.
  • Page 105 XII. Operation E. Boiler Sequence Of Operation (continued) 2. Using The Display The Control includes a touch screen LCD display. The user monitors and adjusts boiler operation by selecting screen navigation “buttons” and symbols. The “Home Screen” and menu selections are shown below. When no selection is made, while viewing any screen, the display reverts to the “Home Screen”...
  • Page 106 XII. Operation E. Boiler Sequence Of Operation (continued) 3. Status Screens Boiler Status screens are the primary boiler monitoring screens. The user may simply “walk” though boiler operation by repeatedly selecting the right or left “arrow” symbol. These screens are accessed by selected the “Status” button from the “Home”...
  • Page 107 XII. Operation E. Boiler Sequence Of Operation (continued) 3. Status Screens (continued) Bargraph Screen The bargraph screen presents measured values for easy comparison. Pumping is a major part of any hydronic system. This screen provides the status of the boiler’s demand to connected pumps as well as the status of Frost Protection and pump Exercise functions.
  • Page 108 XII. Operation E. Boiler Sequence Of Operation (continued) 3. Status Screens (continued) Zone Control Status Screens Zone Control Status Screen provides status and a page links for up to four zone panels. Individual zone “on” status is shown by a bold zone number with a solid underscore.
  • Page 109 XII. Operation E. Boiler Sequence Of Operation (continued) 5. Multiple Boiler Sequencer Screens available When the Sequence Master is enabled the following screen is The Sequencer Status screen is selected by “pressing” “Status” button from the “Home” screen when Sequence Master is enabled. 106375-01 - 4/16...
  • Page 110 XII. Operation (continued) F. Changing Adjustable Parameters Adjust Mode 1. Entering Adjust Mode Warning! Improper settings or service The Control is factory programmed create risk of property For Service Contact: to include basic modulating boiler damage, injury or death. CONTRACTOR NAME functionality.
  • Page 111 XII. Operation F. Changing Adjustable Parameters (continued) 2. Adjusting Parameters (continued) The following pages describe the Control’s adjustable parameters. Parameters are presented in the order they appear on the Control’s Display, from top to bottom and, left to right. From the “Home” screen select the Adjust button to access the adjustment mode screens show below (if required, refer to the previous page to review how to enter Adjustment mode): System “Press”...
  • Page 112 XII. Operation F. Changing Adjustable Parameters (continued) 2. Adjusting Parameters (continued) WARNING Asphyxiation Hazard. Boiler type is factory set and must match the boiler model. Only change the boiler type setting if you are installing a new or replacement Control. The boiler type setting determines minimum and maximum blower speeds.
  • Page 113 XII. Operation F. Changing Adjustable Parameters (continued) Table 12.10: Parameters Changed Using the Boiler Type Parameter Selections: Control Repair Part Kit 107093-01 Altitude 0 - 4,500 Ft. Model K2FT-085-04 K2FT-110-04 K2FT-155-04 K2FT-205-04 K2FT-270-04 Maximum Heat Rate (RPM) 5400 5300 5400...
  • Page 114 XII. Operation F. Changing Adjustable Parameters (continued) Expected Heat Rate Adjustment Screens (HeatMatch Software) The Control is shipped with defaults that will provide improved operation. Adjustment is only required to optimize setup. The expected heat rate adjustment is used to better match boiler output to the home heating needs. After receiving a “call for heat”...
  • Page 115 XII. Operation F. Changing Adjustable Parameters (continued) “Press” button to access the following parameters: Factory Setting Range / Choices Parameter and Description System Pump run pump for: Activates the system pump output according to selected function. Never: Pump is disabled and not shown on status screen. Never, Any Demand: Pump Runs during any call for heat.

  • Page 116: Parameter Selection

    XII. Operation F. Changing Adjustable Parameters (continued) Example Pump Parameter selections: Single boiler with no Indirect Water Heater At least eight pipe diameters upstream of first tee. Relief Valve No further apart than 12" (~30 cm) or four pipe diameters, whichever is smaller. From At least 18"...
  • Page 117 XII. Operation F. Changing Adjustable Parameters (continued) Example Pump Parameter selections (continued): Single Boiler with Supply Piped IWH, System and DHW Wired to Master At least eight pipe diameters upstream of first tee. Parameter Selections: No further apart than 12" (~30 cm) or four pipe diameters, whichever is smaller. At least 18"...
  • Page 118 XII. Operation F. Changing Adjustable Parameters (continued) Example Pump Parameter selections (continued): Multiple boilers IWH Piped to Primary, Optional Domestic Hot Water Priority Sequencer Master Boiler 2 (Boiler 1) Wiring locations: Thermostat DHW call for heat System pump DHW pump Boiler Pump Sequencer Master Parameter Selections: Sequencer Master...
  • Page 119 XII. Operation F. Changing Adjustable Parameters (continued) “Press” button to access the following parameters: Factory Setting Range / Choices Parameter and 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...
  • Page 120 XII. Operation F. Changing Adjustable Parameters (continued) “Press” button to access the following parameters: Factory Range / Choices Parameter and Description Setting Central Heat Setpoint 180°F 60°F to 190°F (82.2°C) (16°C to 87.8°C) Target temperature for the central heat priority. Value also used by the outdoor air reset function. Central Heat Diff Above The boiler stops when the water temperature rises ‘Diff Above’...
  • Page 121 XII. Operation F. Changing Adjustable Parameters (continued) “Press” button to access the following parameters: Factory Range / Choices Parameter and Description Setting Auxiliary Heat Setpoint 180°F 60°F to 190°F Target temperature for the Auxiliary Heat priority. Value also used by the outdoor air reset (82.2°C) (16°C to 87.8°C) function.
  • Page 122 XII. Operation F. Changing Adjustable Parameters (continued) “Press” button to access the following parameters: Factory Range / Choices Parameter and Description Setting Domestic Hot Water Setpoint 170°F 60°F to 190°F The Domestic Hot Water (DHW) Setpoint parameter is used to create a minimum boiler water (76.7°C) (16°C to 87.8°C) temperature setpoint that is used when DHW heat demand is “on”.
  • Page 123 XII. Operation F. Changing Adjustable Parameters (continued) “Press” button to access the following parameters: Factory Range / Choices Parameter and Description Setting Central Heat Outdoor Reset Enable If an outdoor sensor is installed and Outdoor Reset is Enabled, the boiler will automatically adjust the heating zone set point temperature based on the outdoor reset curve in Figure 8.
  • Page 124 XII. Operation F. Changing Adjustable Parameters (continued) “Press” button to access the following parameters: Factory Range / Choices Parameter and Description Setting Auxiliary Heat Outdoor Reset Enable If an outdoor sensor is installed and Outdoor Reset is Enabled, the boiler will automatically adjust the heating zone set point temperature based on the outdoor reset curve in Figure 8.
  • Page 125 XII. Operation F. Changing Adjustable Parameters (continued) Figure 12.13: Outdoor Reset Curve Central Heat Central Heat Heating Element Type Heating Element Type Setpoint Setpoint 180°F to 190°F 100°F to 140°F In Slab Radiant High Fan Coil (82.2°C to 87.8°C) (37.8°C to 60°C) Mass Radiant Convection 160°F to 190°F...
  • Page 126 XII. Operation F. Changing Adjustable Parameters (continued) “Press” button to access the following parameters: Factory Range / Choices Parameter and Description Setting Master Enable/Disable Enable, Disable The Sequencer Master Enable/Disable is used to “turn on” the Multiple Boiler Controller. Disable Warning! enable ONLY one Sequence Master.
  • Page 127 XII. Operation F. Changing Adjustable Parameters (continued) “Press” button to access the following parameters: Factory Range / Parameter and Description Setting Choices Central Heat Modulation Source This parameter enables the 4-20mA input to control firing rate and the thermostat input to control boiler on/off demand directly without using the internal setpoint.

  • Page 128: Xiii. Service And Maintenance

    XIII. Service and Maintenance Important Product Safety Information Refractory Ceramic Fiber Product Warning: The Repair Parts list designates parts that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to temperatures above 1805°F, such as during direct flame contact, RCF changes into crystalline silica, a known carcinogen.
  • Page 129 XIII. Service and Maintenance (continued) WARNING Asphyxiation Hazard. Fire Hazard. Explosion 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 130 XIII. Service and Maintenance (continued) NOTICE Warranty does not cover boiler damage or malfunction if the following steps are not performed at the intervals specified. 1) Continuously: Keep the area around the boiler free from combustible materials, gasoline and other flammable vapors and liquids.
  • Page 131 XIII. Service and Maintenance (continued) Flexible Gas line When disconnecting flexible gas line, Connection place a backup wrench on this nut to prevent damage to gas valve Figure 13.1: Disconnecting Flexible Gas Line Flame Sensor Igniter Figure 13.2: Igniter and Flame Sensor Location 106375-01 - 4/16...
  • Page 132 XIII. Service and Maintenance (continued) Unplug the igniter, ground, and flame sensor wires from the ignition electrode and the flame sensor (Figure 13.2). Use a 10 mm wrench to remove fire door to the heat exchanger (Figure 13.2). Carefully remove the door/blower/ gas valve assembly from the heat exchanger, being careful not to damage the refractory insulation on the inside of the door (see Refractory Warning on page 128) or the electrodes.
  • Page 133 XIII. Service and Maintenance (continued) 0.177in±0.02 4.5mm±0.5 Figure 13.3: Igniter Gap INLET NUT INLET GASKET VENT BOILER JACKET OUTLET NUT CONDENSATE DRAIN #10-32 SHCS CORRUGATED DRAIN TUBE CONDENSATE TRAP BRACKET CONDENSATE TRAP COLLAR #10 SPLIT LOCK CONDENSATE TRAP WASHER #10-32 HEX NUT #8-18 THREAD FORMING CLEAN OUT CAP SCREW (1/4"...
  • Page 134 XIII. Service and Maintenance (continued) Refer Section VII “Venting” to re-assemble any vent system components that are disassembled during this inspection and for details on supporting, pitching, and terminating the vent system. Reconnect any wiring which has been disconnected. Inspect the hydronic system. Look for leaks and repair any found. If system contains antifreeze, or other additives, test and/or maintain them as directed by the additive manufacturer.

  • Page 135: Xiv. Troubleshooting

    XIV. Troubleshooting WARNING Electrical Shock Hazard. Turn off power to boiler before working on wiring. A. Troubleshooting problems where no error code is displayed. Condition Possible Cause Boiler not responding to call for heat, “Status” and Boiler is not seeing call for heat. Check thermostat or zone wiring for loose connection, “Priority”...
  • Page 136 XIV. Troubleshooting (continued) C. Help Screen Faults Indication Condition Possible Cause Zone Panel 1 communication lost, typical for Panel 1 through 4: The zone panel’s communication was established and then lost. Check the following to correct the Zone Panel 1 issue: •...
  • Page 137 XIV. Troubleshooting (continued) E. Active Fault Screen Faults Indication Condition Possible Cause The Limit String Status screen shows the safety limit status. A contact icon, either “open” or “closed”, graphically represents each safety limit. The “closed” contact icon Limit String Status is steady;...

  • Page 138: Lockout Condition

    XIV. Troubleshooting (continued) F. Troubleshooting problems where a Soft Lockout Code is displayed. When a soft lockout occurs, the boiler will shut down, the display will turn red and the “Help” button will “blink”. Select the “blinking” “Help” button to determine the cause of the soft lockout.
  • Page 139 XIV. Troubleshooting (continued) Soft Lockout Codes Displayed (continued) Lockout Condition Possible Cause Number • Shorted or mis-wired flame rode wiring. • Flame rod shorted to ground Flame rod • Defective flame rod. • Condensate Trap plugged. shorted to ground • Plugged drain line in trap.
  • Page 140 XIV. Troubleshooting (continued) G. Troubleshooting problems where a Hard Lockout Code is displayed. When a hard lockout occurs, the boiler will shut down, the display will turn red and the “Help” button will “blink”. Select the “blinking” “Help” button to determine the cause of the Hard Lockout.

  • Page 141: Xv. Repair Parts

    XV. Repair Parts All K2FT™ Series Repair Parts may be obtained through 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 Description K2FT-085 K2FT-110 K2FT-155 K2FT-205 K2FT-270 Heat Exchanger Contact U.S. Boiler Company. Provide boiler serial number. Burner Repair Kit (includes burner and screws) 106986-01 106986-02 106986-03 106986-04 Burner Screw, Socket Head Cap Screw, M4 x 6mm, 101064-01 (3) 101064-01 (4)
  • Page 143 Repair Parts (continued) Space Heating Models: • K2FT-085 • K2FT-110 • K2FT-155 • K2FT-205 • K2FT-270 106375-01 - 4/16...
  • Page 144 (continued) 155 MBH Combi Heat Exchanger and Piping Repair Parts Part Number (Qty) Description K2FTC-155 Contact U.S. Boiler Company. Heat Exchanger Provide boiler serial number. Burner Repair Kit (includes burner and screws) 106986-03 Burner Screw, Socket Head Cap Screw, M4 x 6mm, 316SS...
  • Page 145 XV. Repair Parts (continued) Combi Domestic Hot Water and Space Heating Model: • K2FTC-155 106375-01 - 4/16...
  • Page 146 Repair Parts (continued) All Models Blower and Gas Train Repair Parts Part Number (Qty) Description K2FT-155 & K2FT-085 K2FT-110 K2FT-205 K2FT-270 K2FTC-155 Blower Repair Kit (includes blower, hardware and 107001-01 107001-02 107001-03 gaskets) Blower Outlet Gasket Repair Kit 106029-01 Blower Control Harness Repair Kit (4 wire harness)
  • Page 147 Repair Parts (continued) All Models 106375-01 - 4/16...
  • Page 148 Repair Parts (continued) Space Heating Models Jacket Repair Parts Part Number (Qty) Description K2FT-085 K2FT-110 K2FT-155 K2FT-205 K2FT-270 Front Door Assembly Repair Kit (includes door, plastic 107016-01 trim and hardware) Door Latch Catch 106145-01 (4) Door Grounding Latch (includes catch and keeper)
  • Page 149 106375-01 - 4/16...
  • Page 150 Repair Parts (continued) 155 MBH Combi Jacket Repair Parts Part Number (Qty) Description K2FTC-155 Front Door Assembly Repair Kit (includes door, plastic 107016-01 trim and hardware) Door Latch Catch 106145-01 (4) Door Grounding Latch (includes catch and keeper) 106093-01 Control Panel Frame Assembly w / Gaskets 106577-01 Jacket Screw, 8-18 x 1/2"...
  • Page 151 106375-01 - 4/16...
  • Page 152 Repair Parts (continued) All Models Control Panel Repair Parts Part Number (Qty) Key No. Description K2FT-155 & K2FT-085 K2FT-110 K2FT-205 K2FT-270 K2FTC-155 Control Panel 106290-01 Transformer Repair Kit 106034-01 Jacket Screw, 8 -18 x 1/2" Long, Type B 105368-01 Door Latch Keeper...
  • Page 153 106375-01 - 4/16...
  • Page 154 Repair Parts (continued) 2" CPVC/PVC Sidewall Vent Components Part Number (Qty) Description K2FT-155 & K2FT-085 K2FT-110 K2FT-205 K2FT-270 K2FTC-155 2" PVC Sidewall Vent Kit (includes items 7B 107039-01 Not Permitted through 7H) 2" x 30" Sched. 40 CPVC Pipe 106612-01 Not Permitted 2"...
  • Page 155 Repair Parts (continued) All Models Wire Harness Repair Parts Part Number (Qty) Description K2FT-155 & K2FT-085 K2FT-110 K2FT-205 K2FT-270 K2FTC-155 Low Voltage / Communication Harness Repair Kit 107036-01 High Voltage Harness Repair Kit 107037-01 Ignition Cable Harness Repair Kit 107038-01...
  • Page 156 Appendix A: Instructions for Conversion of this Boiler for use with LP Gas DANGER These instructions include a procedure for adjusting the air-fuel mixture on this boiler. This procedure requires a combustion analyzer to measure the CO2 (or Oxygen) and Carbon Monoxide (CO) levels in flue gas.
  • Page 157 Appendix A - (continued) 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. WARNING The pressure regulator has been factory set using precision instruments and must never be adjusted in the field.
  • Page 158 Appendix A - (continued) Offset Regulator - Do Not Adjust Outlet Tap Gas Inlet Inlet Tap Gas Outlet Throttle Screw Tube to Air Proving Switch Figure A.3: Gas Valve Detail Table A.4: Starting Number of Throttle Turns for Conversion to LP Gas Model # Counter-clockwise Turns Size...
  • Page 159 Appendix A - (continued) 7) Perform a combustion test, sampling flue products from the tap in the front of the vent adaptor. 8) While the burner is at high fire adjust the throttle as needed to obtain the CO (or O ) settings shown in the Table A.5: •...

  • Page 160: Appendix B: Instructions For High Altitude Installation Above 4,500 Ft

    Appendix B: Instructions for High Altitude Installations Above 4,500 ft. These instructions apply only to the following altitude ranges: 4501 ft.- 6000 ft., 6001 ft.- 7800 ft., 7801 ft.- 10,100 ft. operation. These instructions contain specific information to setup your boiler to ensure proper WARNING LP Conversions - boiler setup from factory is configured for use with natural gas installed from 0 - 4,500 ft.
  • Page 161 Appendix B - (continued) 4. After 5 minutes of operation check CO and CO 6. Start boiler five times at the above settings to ensure (Air-Free) and ensure it is within the limits outlined boiler lights off without delay and without noise. in Table B.3.
  • Page 162 Appendix B - (continued) Table B.2: Altitude Adjustments (Above 4500 ft. only) Percentage derate Altitude Model Fuel (Approx. per 1000 feet) K2FT-085 NG / LP 0.0% K2FT-110 NG / LP 0.0% K2FT-155 & K2FTC-155 NG /LP 0.0% K2FT-205 1.6% K2FT-205 0.0%...
  • Page 163 6001- 7801- 4501- 6001- 7801- 6000 ft. 7800 ft. 10,100 ft. 6000 ft. 7800 ft. 10,100 ft. 6100 6650 7200 1600 1700 1800 K2FT-085 6100 7000 7200 1600 1700 1800 6450 6900 7200 1600 1700 1800 K2FT-110 6450 6900 7200...

  • Page 164: Appendix C: K2Ftc-155 Combi Instruction Manual

    Appendix C: K2FTC-155 Combi Instruction Manual – Product Description The K2FTC-155 provides economical, reliable, tank-less domestic hot water (DHW) production in addition to central space heating provided by the K2FT high efficiency boiler. – Domestic Hot Water Basic Operation The K2FTC-155 Combi provides central heat through a high efficiency stainless steel heat exchanger and DHW through a flat plate heat exchanger.
  • Page 165 Appendix C - (continued) 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 shall be consulted before installations are made.
  • Page 166 Appendix C - (continued) DANGER Electrical Shock Hazard. Positively assure all electrical connections are unpowered before attempting installation or service of electrical components or connections of the boiler or building. Lock out all electrical boxes with padlock once power is turned off. Water temperature above 120°F (49°C) can cause serious injury.
  • Page 167 Appendix C - (continued) – Introduction 1. Parts Included: 3 copper pipe assemblies, thermostatic mixing valve, flow switch, and miscellaneous parts bag. 2. Install boiler per installation instructions. Attach supply and return piping at bottom of jacket (See Figure C.1). 3.
  • Page 168 Appendix C - (continued) – Piping Diagram At least eight pipe diameters upstream of first tee. No further apart than 12" (~30 cm) or four pipe diameters, whichever is smaller. Y-Strainer From At least 18" (~46 cm) of straight pipe for Conventional Air Scoop. (Recommended) System Relief...
  • Page 169 Appendix C - (continued) Tools Needed: • Pliers • 1/2 inch open-end wrench • Adjustable wrench • Flat Head screwdriver • Electric drill with extension • Phillips head screwdriver, Standard and small • Small flat-head screwdriver – General Installation Instructions ...
  • Page 170 Appendix C - (continued) 5. Install short pipe to mix end of mixing valve. Install flow switch to mixed water outlet pipe. Ensure that flow direction arrow points away from mixing valve. NOTICE Proper installation of the flow switch is required for the boiler to fire and produce domestic hot water.
  • Page 171 Appendix C - (continued) WARNING To complete service and place boiler back into operation, follow “Start-up and Checkout” Section in this manual. XIII – Boiler Control Set-up 18. Turn on boiler power 19. From boiler home screen, select “Adjust” and login. 20.
  • Page 172 Appendix C - (continued) – Troubleshooting Enough Hot Check to see if hot water flowrate is greater than 0.54 gpm. Water Flow? Boiler priority In DHW settings, enable priority. Running? Flow switch Arrow on flow switch should point in direction of flow. installed (from mix valve to sweat connection) correctly?
  • Page 173 Appendix C - (continued) XVIII - Domestic Actuator Replacement 1. Switch power supplies OFF. Disconnect electrical leads, carefully noting the position and color of each lead. 2. Please the manual operating level in the manual open position. 3. Remove actuator by depressing locking button and lifting straight up. 4.

  • Page 174: Commonwealth Of Massachusetts

    Appendix D: Special Requirements For Side-Wall Vented Appliances In The Commonwealth of Massachusetts 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 used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) ft.
  • Page 175 Appendix D - (continued) 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 manufacturer of a Product 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 satisfied by the manufacturer:...
  • Page 176 U.S. Boiler Company, Inc. P.O. Box 3020 Lancaster, PA 17604 1-888-432-8887 www.usboiler.net 106375-01 - 4/16...

This manual is also suitable for:

K2ft-110K2ft-270K2ftc-155K2ft-205K2ft-155

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