Page 1 DIRECT VENT GAS - FIRED HOT WATER BOILER 9700609 as an EnErgY STar Partner, U.S. Boiler Company has determined that the K2WT™ Series meets the EnErgY ® STar guidelines for energy efficiency established by the United States Environmental Protection Agency (EPA).
Page 2 The City of New York requires a Licensed Master Plumber supervise the installation of this product. The Massachusetts Board of Plumbers and Gas Fitters has approved the K2WT™ Series boiler. See the Massachusetts Board of Plumbers and Gas Fitters website, http://license.reg.state.ma.us/pubLic/pl_products/pb_pre_form.asp for the latest Approval Code or ask your local Sales Representative.
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 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 INSPECT THE BOILER ANNUALLY. To keep your DO NOT BLOCK AIR FLOW into or around the boiler safe and efficient, have a service technician boiler.
Page 5: Table Of Contents
Table of Contents Product Description II. Specifications III. Before Installing Locating The Boiler Mounting The Boiler Air For Ventilation VII. Venting A. Vent System Design B. Design Requirements Unique to Horizontal Twin Pipe Venting Systems C. Design Requirements Unique to Vertical Venting Systems D.
Page 6: Product Description
i. Product Description 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 be 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.
Page 7: Before Installing
1/2” * The Net AHRI Water Ratings shown are based on a piping and pickup allowance of 1.15. The manufacturer should be consulted before selecting a boiler for installations having unusual piping and pickup requirements, such as intermittent system operation, extensive piping systems, etc.
Page 8: Locating The Boiler
iii. Before installing (continued) 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 converting it in accordance with the instructions shown in appendix a. •...
Page 9 iV. Locating the Boiler (continued) *LEFT SIDE CLEARANCE MAY BE REDUCED TO 1/2" HOWEVER RELIEF VALVE MUST REMAIN IN SAME SPACE AS BOILER. 107110-01 - 6/16...
Page 10: Mounting The Boiler
V. Mounting The Boiler A. Wall Mounting CaUTiOn This boiler weighs as much as 119 pounds: • 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.
Page 11 V. Mounting The Boiler (continued) Figure 5.1 Wall Layout/Mounting Hole Location 107110-01 - 6/16...
Page 12 V. Mounting The Boiler (continued) Figure 5.2 Boiler Mounting Bracket Installation / Boiler Wall Mounting 107110-01 - 6/16...
Page 13: 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 14: 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 15 Vii. Venting A. Vent System Design (continued) Figure 7.0a: Horizontal Twin Pipe Figure 7.0b: Vertical Twin Pipe Figure 7.0c: Split Venting 107110-01 - 6/16...
Page 16 Vii. Venting A. Vent System Design (continued) • DuraVent PolyPro - ULC S636 listed Polypropylene special gas vent system. • Selkirk Polyflue - ULC S636 listed Polypropylene special gas vent system. • Centrotherm InnoFlue SW - ULC S636 listed Polypropylene special gas vent system. Use PVC and/or CPVC for the air intake system. PVC may be used for all air intake piping between the intake terminal and the boiler. When CPVC and/or PVC pipe is used, it must be joined using primer and cement that is listed for use with the pipe material being joined (PVC, CPVC, or CPVC to PVC).
Page 17 Vii. Venting A. Vent System Design (continued) 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 combustible and non-combustible walls - see 9 below) • Air Intake - 0”...
Page 18 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. • Support Centrotherm InnoFlue horizontally every 39 inches with additional supports at elbows and vertically every 78”. • Support 2” Selkirk Polyflue horizontally every 30”. Support 3” Polyflue horizontally every 39”. Support vertical runs of both 2” and 3” Polyflue every 16 ft. Les instructions d´installation du système d´évacuation doivent préciser que les sections horizontales doivent être supportées pour prévenir le fléchissement. Les méthodes et les intervalles de support doivent être spécifiés. Les instructions divent aussi indiquer les renseignements suivants: • les chaudières de catégories II et IV doivent être installées de façon à empêcher l´accumulation de condensat: et...
Page 19 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 107110-01 - 6/16...
Page 20: 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 – 7.10. In addition to the requirements in Section VII - A, observe the following design requirements: Permitted Terminals for Horizontal Venting: Terminal Option A: Fittings (Acceptable for Vent Options 1-8) –...
Page 21 2” 3” 2” 3” 2” 3” Nominal Diameter Intake 2” 3” 2” 3” 2” 3” 2” 3” Min Equivalent Vent Length: K2WT-080 12” 12” 12” 12” 12” 12” 12” 12” K2WT-100 12” 12” 12” 12” 12” 12” 12” 12” K2WT-120 12”...
Page 22 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 23 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 24 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 25 Vii. Venting B. Design Requirements Unique to Horizontal Twin Pipe Venting Systems (continued) 107110-01 - 6/16...
Page 26: 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 27 2” 3” 2” 3” 2” 3” Nominal Diameter Intake 2” 3” 2” 3” 2” 3” 2” 3” Min Equivalent Vent Length: K2WT-080 12” 12” 12” 12” 12” 12” 12” 12” K2WT-100 12” 12” 12” 12” 12” 12” 12” 12” Models K2WT-120 12”...
Page 28 2” 3” Nominal Diameter Intake 2” or 3” 3” 2” or 3” 3” Min B Vent ID 5” 6” 5” 6” Min Equivalent Vent Length: K2WT-080 36” 36” 36” 36” K2WT-100 36” 36” 36” 36” K2WT-120 36” 36” Models K2WT-150 Not Permitted 52”...
Page 29 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 Section VII - E of this manual and the DiversiTech instructions provided with the terminal, for installation details.
Page 30 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 31 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) 107110-01 - 6/16...
Page 32 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 33 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) 107110-01 - 6/16...
Page 34: 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 Section VII - A, observe the following design requirements: 1.
Page 35 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”...
Page 36 2” 3” 2” 3” 2” 3” Nominal Diameter Intake 2” or 3” 3” 2” or 3” 3” 2” or 3” 3” Min Equivalent Vent Length: K2WT-080 48” 48” 48” 48” 48” 48” K2WT-100 48” 48” 48” 48” 48” 48” K2WT-120 48”...
Page 37 Vii. Venting D. Design Requirements Unique to Split Vent Systems (continued) Table 7.21: Summary of Split Vent System Options (cont.) 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 38 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) 107110-01 - 6/16...
Page 39 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) 107110-01 - 6/16...
Page 40 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 107110-01 - 6/16...
Page 41: Assembly Of Cpvc/Pvc Vent Systems
Vii. Venting E. Assembly of CPVC/PVC Vent Systems (continued) E. Assembly of CPVC/PVC Vent Systems 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 (supplied with the boiler) for near-boiler vent piping before transitioning to Schedule 40 PVC pipe (ASTM 2665) components for remainder of vent system.
Page 42 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 exceeding 4ft.
Page 43 Vii. Venting E. Assembly of CPVC/PVC Vent Systems (continued) Figure 7.28: installation of Standard Horizontal Terminals Figure 7.29: installation of Standard Vertical Terminals 107110-01 - 6/16...
Page 44 Vii. Venting E. Assembly of CPVC/PVC Vent Systems (continued) 5. Installation of Vertical Fitting Terminals (Terminal Option H): a. See Figure 7.29 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 45 Vii. Venting E. Assembly of CPVC/PVC Vent Systems (continued) Figure 7.30: Installation of IPEX Low Profile Terminal Through Sidewall Figure 7.31: Installation of DiversiTech Low Profile Terminal Through Sidewall 107110-01 - 6/16...
Page 46 Vii. Venting E. Assembly of CPVC/PVC Vent Systems (continued) Figure 7.32: Cutting IPEX and DiversiTech Concentric Vent Terminals Figure 7.33: Installation of IPEX and DiversiTech Concentric Terminal through Sidewall 107110-01 - 6/16...
Page 47 Vii. Venting E. Assembly of CPVC/PVC Vent Systems (continued) Figure 7.34: 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 Section VII - C of this manual for permitted terminal locations).
Page 48: 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 49 Vii. Venting F. Assembly of DuraVent PolyPro Vent Systems (continued) 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” clearance hole into the front side of the air intake adapter. Insert the first piece of PVC air intake pipe into the air intake connection and drill a 1/8”...
Page 50 Vii. Venting F. Assembly of DuraVent PolyPro Vent Systems (continued) 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 107110-01 - 6/16...
Page 51 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 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. (See Section VII - A of this manual for permitted terminal locations). b.
Page 52 Vii. Venting F. Assembly of DuraVent PolyPro Vent Systems (continued) Figure 7.39: Installation of Duravent PolyPro Concentric Vent Terminal Through Sidewall Figure 7.40: Installation of Duravent PolyPro Concentric Terminal Through Roof 107110-01 - 6/16...
Page 53: Assembly Of Selkirk Polyflue Vent Systems
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 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 54 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 adaptor, it is IMPOSSIBLE to remove it. Make sure the correct type of pipe is selected, and that it is of the correct length, before inserting it into the vent adaptor.
Page 55 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 56 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 107110-01 - 6/16...
Page 57: 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 58 Vii. Venting H. Assembly of Centrotherm InnoFlue Vent Systems 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” clearance hole into the front side of the air intake adapter. Insert the first piece of PVC air intake pipe into the air intake connection and drill a 1/8”...
Page 59 Vii. Venting H. Assembly of Centrotherm InnoFlue Vent Systems 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 107110-01 - 6/16...
Page 60 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 61: Condensate Trap And Drain
Vii. Venting I. Condensate Trap and Drain Line (continued) I. Condensate Trap and Drain Line All condensate which forms in the boiler or vent system passes through the heat exchanger and out of a bottom drain port which is connected to the condensate trap with a hose. This trap allows condensate to drain from the heat exchanger while retaining flue gases in the boiler. This trap is an integral part of the boiler but must be connected to a drain pipe as shown in Figure 7.47.
Page 62: Removing An Existing Boiler From Common Chimney
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 63: 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 64 It is very important that the gas line is properly purged by the gas supplier or utility company. Figure 8.1: gas Connection to Boiler Table 8.2: Minimum and Maximum Inlet Pressures Model Max. (Natural & LP) Min. (Natural) Min. (LP) K2WT-080 14.0” 2.5” 11.0” K2WT-100 14.0” 2.5”...
Page 65: 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 66: Standard Piping Installation Requirements
There are two basic methods that can be used to pipe this boiler into the system. Method #1 (primary-secondary piping) is always preferred. Additional information on hydronic system design can be found in the I=B=R Guide RHH published by the Air-Conditioning, Heating and Refrigeration Institute (AHRI). Table 9.1: Flow Limitations...
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Page 71 Equivalent Length of 30 ft or Less * Equivalent Length of 60 ft or Less * Approx. Flow Approx. Rise (°F) Approx. Flow Approx. Rise Boiler Model Boiler Model (GPM) (GPM) (°F) K2WT-080 K2WT-080 K2WT-100 K2WT-100 K2WT-120 K2WT-120 K2WT-150 12.9 K2WT-150 11.9 K2WT-180 12.9...
Page 73 IX. System Piping (continued) 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 will equal the flow rate through the system. The flow rate through the system must therefore always remain within the limits shown in Table 9.1. For this reason, the pressure drop through the entire system must be known. This method is generally not recommended because it is often very difficult to accurately calculate the pressure drop through the system.
Page 74 IX. System Piping (continued) Note: These curves show the flow that can be achieved through the boiler as a function of the pressure drop through the connected piping. Figure 9.8a: Taco Net Circulator Performance Curve Figure 9.8b: Grundfos Net Circulator Performance Curve Note: Must use Speed HI to achieve the flow requirement shown in Table 9.1 107110-01 - 6/16...
Page 75: Near Boiler Piping Design
IX. System Piping (continued) 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 fittings provided. ASME Section IV currently requires that this relief valve be installed above the heat exchanger as shown.
Page 76 IX. System Piping (continued) 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 boiler. This is a water tube boiler and this flow switch is therefore the only effective way to provide such protection. Section HG614(c ) of the 2013 ASME boiler and Pressure Vessel Code recognizes the use of a listed flow switch in lieu of a low water cut-off on water tube boilers.
Page 77: 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. • Systems with routine additions of fresh water. • Systems which are open to the atmosphere. If the boiler is to be used in such a system, it must be separated from the oxygenated water being heated with a heat exchanger as shown in Figure 9.10.
Page 78: 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 79 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. Depending on the DHW configuration, it may also be on during a call for DHW.
Page 80 X. Wiring (continued) Figure 10.2: High Voltage PCB Terminal Connections Figure 10.3: Low Voltage PCB Terminal Connections 107110-01 - 6/16...
Page 81 X. Wiring (continued) • 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) • MODBUS - (A) • MODBUS - (B) • MODBUS - (-V) 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.
Page 82 X. Wiring (continued) Figure 10.4: Proper installation of Header Sensor 107110-01 - 6/16...
Page 83 X. Wiring (continued) Figure 10.5: internal Ladder Diagram 107110-01 - 6/16...
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Page 86 X. Wiring (continued) Table 10.7: Internal Wire Connection Markings Cross Reference Table 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...
Page 87 X. Wiring (continued) Figure 10.8: TACO SR504 or Equivalent Zone Panel Wiring Connection Diagram 107110-01 - 6/16...
Page 88 X. Wiring (continued) Figure 10.9: Sage Zone Control Circulator Panel Wiring Connection Diagram 107110-01 - 6/16...
Page 89: 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 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 90 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 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 91 XI. Start-Up and Checkout (continued) MANUAL AIR VENT ATTACH 1/4" ID CLEAR TUBING TO HOSE BARB AND ROUTE TO SAFE PLACE AWAY FROM CONTROLS BEFORE OPENING VENT. FLAME ROD Figure 11.1: Location of Manual air Vent 11) Start the boiler using the lighting instructions on page 95. With the boiler powered up, and with no call for heat, the display should look like Figure 11.2a.
Page 92 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 Figure 11.3: Burner Flame 107110-01 - 6/16...
Page 93 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 94 • Selecting the type of indirect water heater (if any) and location of DHW pumps. • Defining the system pump operation. 20) Adjust the heating and indirect water heater thermostats to their final set points. Table 11.5: Typical Combustion Readings (Sea Level Only) Max. CO Model Fuel air Free K2WT-080 Natural Gas 8.9 - 9.3 4.6 - 5.3 K2WT-080 Propane 10.1 - 10.3 5.3 - 5.6 K2WT-100 Natural Gas 8.9 - 9.3...
Page 95 XI. Start-Up and Checkout (continued) Lighting and Operating Instructions 107110-01 - 6/16...
Page 96: 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 97 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 98 XII. Operation (continued) 5. Outdoor Air Reset If the temperature exceeds 210°F (98.9°C), a manual reset hard lockout results. If the boiler is responding to If an outdoor temperature sensor is connected to the internal Multiple Boiler Control Sequencer, Header the boiler and Outdoor Reset is enabled, the Central Sensor or an External EMS demand and the supply Heat setpoint will automatically adjust downwards as...
Page 99 XII. Operation (continued) 6. Stack High Limit the run time the sequencer automatically rotates the Lead boiler after 24 hours of run time. The Control monitors the flue gas temperature sensor located in the vent connector. If the flue temperature 4. Improved Availability exceeds 194°F (90°C), the control begins to reduce the The following features help improve the heat maximum blower speed. If the flue temperature exceeds availability: 204°F (96°C), a forced boiler recycle results.
Page 100 XII. Operation (continued) 9. Optimized Boiler Modulation 11. Advanced Boiler Sequencing Boiler firing rate is managed to increase smoothly After there is a Call For Heat input, both header water as boilers are started. For example, when a second temperature and boiler firing rate percent are used to start boiler is started the initial firing rate is 100%/2 or 50%, and stop the networked boilers.
Page 101: 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 102 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 103 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 104 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. This screen provides the status of the boilers five (5) possible heat demands.
Page 105 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 106 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. 107110-01 - 6/16...
Page 107 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 108 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” button to access the following parameters: Setup Factory Range /...
Page 109 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 110 Model K2WTC-155-04 Maximum Heat Rate (RPM) 5400 Minimum Heat rate (RPM) 1400 altitude 4,501 - 6,000 ft Model K2WT-080-46 K2WT-100-46 K2WT-120N-46 K2WT-150N-46 K2WT-180N-46 Maximum Heat Rate (RPM) 6100 6450 6500 7500 7000 Minimum Heat rate (RPM) 1600 1600 1600 1700...
Page 111 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” the Control first uses the expected heat rate value to set a maximum heat rate. The maximum heat rate is the highest heat rate that the boiler can fire to at that moment. The maximum heat rate is the summation of the expected heat rates for the active (turned on) zones. After establishing the maximum heat rate the Control then measures water temperature and fires the boiler only...
Page 112 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 113 XII. Operation F. Changing Adjustable Parameters (continued) Example Pump Parameter selections: Single boiler with no Indirect Water Heater Parameter Selection: System pump = “Central Heat, Optional Priority” Boiler pump = “any demand” DHW pump = “never” Explanation: This piping arrangement only services central heat.
Page 114 XII. Operation F. Changing Adjustable Parameters (continued) Example Pump Parameter selections (continued): Single Boiler with Supply Piped IWH, System and DHW Wired to Master Parameter Selections: System Pump = “Central Heat, Optional Priority” Boiler Pump = “any demand” DHW Pump = “Primary Loop Piped IWH” DHW Priority Enable is optional Explanation: When call for Domestic Hot Water is received...
Page 115 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 116 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 117 XII. Operation F. Changing Adjustable Parameters (continued) “Press” button to access the following parameters: Factory Range / Choices Parameter and Description Setting 180°F 60°F to 190°F Central Heat Setpoint (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 118 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 119 XII. Operation F. Changing Adjustable Parameters (continued) “Press” button to access the following parameters: Factory Range / Choices Parameter and Description Setting Domestic Hot Water Heater Type Tank Selected when boiler is piped to an indirect water heater. Tankless Selected when a K2 Combi Kit is attached to the boiler. Tank Tankless When selected, special parameters are entered to allow the required Combi rate of...
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 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 121 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 122 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 123 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 124 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 125: 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 126 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 127 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 128 XIII. Service and Maintenance (continued) Figure 13.1: Disconnecting Flexible Gas Line Figure 13.2: Flame ionization Electrode and ignition Electrode Location 107110-01 - 6/16...
Page 129 XIII. Service and Maintenance (continued) Unplug the ignition, ground, and flame rod wires from the ignition electrode and the flame rod (Figure 13.2). Use a 10 mm wrench to remove the four nuts securing the 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 next page) or the electrodes. Inspect the heat exchanger combustion chamber and vacuum any debris found on the coil surfaces.
Page 130 XIII. Service and Maintenance (continued) Figure 13.3: ignition Electrode gap Figure 13.4: Condensate Trap Exploded Parts View 107110-01 - 6/16...
Page 131 XIII. Service and Maintenance (continued) Refer to 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. Replace any wiring which has been disconnected. Inspect the hydronic system.
Page 132: 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 133 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: Setup •...
Page 134 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 135 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 136 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 137 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 138: Repair Parts
XV. Repair Parts All K2WT™ 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 139 XV. Repair Parts (continued) Part Number (Qty) Key no. Description K2WT-080 K2WT-100 K2WT-120 K2WT-150 K2WT-180 Fixing Clamp Bracket Holding Clamp M4 x 7 Fixing Clamp Screw Contact U.S. Boiler Company; Provide boiler serial number 10 -32 x 1/2” Thread Cutting Screw...
Page 140 XV. Repair Parts (continued) 107110-01 - 6/16...
Page 141 XV. Repair Parts (continued) Part Number (Qty) Key no. Description K2WT-080 K2WT-100 K2WT-120 Blower Repair Kit (includes blower, hardware and 27, 28, 29, 36 107169-01 107170-01 gasket) Blower Outlet Gasket Repair Kit 106029-01 CSST Gas Line Assembly Repair Kit 30, 31, 34...
Page 142 XV. Repair Parts (continued) 107110-01 - 6/16...
Page 143 XV. Repair Parts (continued) Part Number (Qty) Key no. Description K2WT-150 K2WT-180 27, 28, 29, 36 Blower Repair Kit (includes blower, hardware and gasket) 107171-01 Blower Outlet Gasket Repair Kit 106029-01 CSST Gas Line Assembly Repair Kit 30, 31, 34...
Page 144 XV. Repair Parts (continued) Part Number (Qty) Key no. Description K2WT-080 K2WT-100 K2WT-120 K2WT-150 K2WT-180 Condensate Trap Repair Kit (includes 51, 52, 53 105851-01 gasket, bracket and trap ball) Ball for Condensate Trap Repair Kit 105850-01 Vent Fitting Repair Kit...
Page 145 XV. Repair Parts (continued) Part Number (Qty) Key no. Description K2WT-080 K2WT-100 K2WT-120 K2WT-150 K2WT-180 Gasket, Short, Vestibule Frame Contact U.S. Boiler Company Gasket, Long, Vestibule Frame / Control Panel Repair Low Voltage Printed Circuit Board 67, 68, (PCB) Kit (includes Low Voltage PCB and...
Page 146 XV. Repair Parts (continued) 107110-01 - 6/16...
Page 147 XV. Repair Parts (continued) Part Number (Qty) Description K2WT-080 K2WT-100 K2WT-120 K2WT-150 K2WT-180 Transformer Repair Kit 106034-01 Sage 2 Boiler Control Repair Kit 107093-01 Thumb Screw w/Clip Repair Kit [includes (2) 8-32 x 106033-01 13/32 screws and (2) retaining clips]...
Page 148 XV. Repair Parts (continued) 107110-01 - 6/16...
Page 149 Control Panel 104680-01 Display Mounting Bracket 104683-01 Wire Cover Bracket 104685-01 (2) Repair Kit, Front Cover / “K2WT” Decal (includes 107132-01 front panel, logo plate and “K2WT” decal) Cable Holder Anchor Mount (not shown) 105166-01 (3) 5/16 Flat Washer (not shown)
Page 150 XV. Repair Parts (continued) Part Number (Qty) Description K2WT-080 K2WT-100 K2WT-120 K2WT-150 K2WT-180 1”NPT X 2-1/2” Nipple 806600357 1” NPT Tee 806601015 3/4” NPT Boiler Drain Valve 806603061 1”NPT x 2” Nipple 806600004 1” NPT Tee with Side Outlet 105298-01 1”...
Page 151 XV. Repair Parts (continued) Part Number (Qty) Description K2WT-080 K2WT-100 K2WT-120 K2WT-150 K2WT-180 130 3” Stainless Steel Rodent Screen 102191-01 (2) 131 3” X 30” Schedule 40 CPVC Pipe 102193-01 132 3” Schedule 80 CPVC 90° Elbow 102192-01 133 3” PVC Coupling 105292-01 134 3”...
Page 152 XV. Repair Parts (continued) Part Number (Qty) Key no. Description K2WT-080 K2WT-100 K2WT-120 K2WT-150 K2WT-180 Low Voltage / Communication Harness Repair Kit 105869-01 High Voltage Harness Repair Kit 105868-01 142, 143, Repair Kit, Trap/Flame, Trap/Ground, Circulator 105870-01 Pigtail (includes wire harnesses)
Page 153: Appendix A: Lp Gas Conversion Instructions
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 154 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 Model # Counter-clockwise Turns (From Fully Closed) K2WT-080 3-3/4 K2WT-100 K2WT-120 K2WT-150 2-3/4...
Page 155 Appendix A - (continued) 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 (or O ) settings shown in the Table A.3: • To reduce the CO (increase the O ) turn the throttle clockwise • To increase the CO (reduce the O ) turn the throttle counter-clockwise Make adjustments in increments of 1/8 to 1/4 turn and allow the boiler at least a minute to respond to each adjustment before making another.
Page 156: Appendix B: Instructions For High Altitude Installation Above 4,500 Ft
If installing K2WT-080 or K2WT-180, do not attempt to convert K2WT-080 for use with LP at altitudes above 2000 ft. Also, do not attempt to convert K2WT-180 for use with LP gas at altitudes above 7800 ft. Attempts to do so may result in unreliable operation, property damage, personal injury or loss of life due to carbon monoxide (CO) poisoning.
Page 157 B1 of this Supplement, adjust throttle screw altitude prior to startup. Install boiler in accordance such that the CO falls in this range while boiler with the K2WT Installation manual included with is locked manually in high fire. Turning throttle boiler. screw counter-clockwise increases the CO , while 2.
Page 158 Appendix B - (continued) Table B1: K2WT Altitude Adjustments (Above 2000 ft. only) Measured CO Approximate De-rate per 1000 Ft. Model Fuel Derate/1000 ft. Derate/1000 ft. Derate/1000 ft. 2000-4500 ft. 4501-7800 ft. 7801-10,200 ft. 2000-4500 ft. 4501-7800 ft. 7801-10,200 ft.
Page 159: Appendix C: Special Requirements For Side-Wall Vented Appliances In The Commonwealth Of Massachusetts
Appendix C: 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. above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:...
Page 160 Appendix C - (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:...
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Page 164 U.S. Boiler Company, Inc. P.O. Box 3020 Lancaster, PA 17604 1-888-432-8887 www.usboiler.net 107110-01 - 6/16...

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