Burnham K2WT Residential Installation, Operating And Service Instructions
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Burnham K2WT Residential Installation, Operating And Service Instructions

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Installation, Operating and Service Instructions for
K2WT
Residential
9700609
As an ENERGY STAR
®
Company has determined that the K2WT
Series meets the ENERGY STAR
energy efficiency established by the United States
Environmental Protection Agency (EPA).
TO THE INSTALLER:
Affix these instructions adjacent to boiler.
TO THE CONSUMER:
Retain these instructions for future reference.
WARNING:
Improper installation, adjustment, alteration, service or maintenance can cause property
damage, injury, or loss of life. For assistance or additional information, consult a qualified installer, service
agency or the gas supplier. This boiler requires a special venting system. Read these instructions care-
fully before installing.
107672-03 - 5/18
TM
Partner, U.S. Boiler
™
guidelines for
®
Condensing
High Efficiency
Direct Vent
Gas-Fired
Water Boiler
Price - $5.00
1

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Summary of Contents for Burnham K2WT Residential

  • Page 1 Installation, Operating and Service Instructions for K2WT Condensing  High Efficiency  Direct Vent  Gas-Fired  Residential Water Boiler  9700609 As an ENERGY STAR Partner, U.S. Boiler ® Company has determined that the K2WT ™ Series meets the ENERGY STAR guidelines for ®...
  • 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. All wiring on boilers installed in the USA shall be made in accordance with the National Electrical Code and/or local regulations.
  • 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. • Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Read and understand the entire manual before attempting installation, start-up operation, or service.
  • Page 4 WARNINGS FOR THE HOMEOWNER FOLLOW ALL INSTRUCTIONS and warnings DO NOT BLOCK AIR FLOW into or around the printed in this manual and posted on the boiler. boiler. Insufficient air may cause the boiler to produce carbon monoxide or start a fire. INSPECT THE BOILER ANNUALLY.

  • Page 5: Table Of Contents

    Table of Contents Product Description ..........6 Specifications .

  • 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. 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

    II. Specifications (continued) Table 2.2: Specifications D.O.E. Supply Approx. Altitude Range (ft) Maximum Minimum AHRI Net Water Heating Dim. & Return Model* Input Input Rating * Volume Connection Capacity “A” Connection Weight (MBH) (MBH) (MBH) (gal.) Size (NPT) (MBH) Size (NPT) (lb.) K2WT-080B 0.430...

  • 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 proper conversion kit per Table 3.1. Use a combustion analyzer and follow all instructions supplied with conversion kit.
  • 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. 107672-03 - 5/18...

  • 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 107672-03 - 5/18...
  • Page 12 V. Mounting The Boiler (continued) Figure 5.2 Boiler Mounting Bracket Installation / Boiler Wall Mounting 107672-03 - 5/18...

  • 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. •...
  • 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 BOILER 107672-03 - 5/18...
  • 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. •...
  • Page 17 VII. Venting A. Vent System Design (continued) NOTICE Do not exceed maximum vent/combustion air system length. Refer to Tables 7.1B, 7.5, 7.13, and 7.21 in this section for maximum vent/combustion air system length. Use Use only vent and combustion air terminals and terminal locations shown in Tables 7.1B, 7.5, 7.13 and 7.21.
  • Page 18 VII. Venting A. Vent System Design (continued) 7. Supporting Pipe - Vertical and horizontal sections of pipe must be properly supported. Maximum support spacing is as follows: • Support CPVC/PVC horizontally and vertically every 4 feet. • Support DuraVent PolyPro horizontally near the female end of each straight section of pipe and vertically every 10 feet.
  • 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 107672-03 - 5/18...

  • 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 –...
  • Page 21 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 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) PVC VENT PIPE CPVC VENT PIPE PITCH VENT PIPE 1/4" PER (FIRST 30" + ELBOW) FOOT TOWARDS BOILER PVC AIR INTAKE PIPE ALTERNATE ORIENTATION PITCH INTAKE AWAY FROM BUILDING EXTERIOR BOILER IF POSSIBLE BOILER ROOM...
  • 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) PITCH VENT PIPE 5/8" PER FOOT TOWARDS BOILER 2"...
  • Page 25 VII. Venting B. Design Requirements Unique to Horizontal Twin Pipe Venting Systems (continued) 107672-03 - 5/18...

  • 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 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 28 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 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) 107672-03 - 5/18...
  • 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) 107672-03 - 5/18...

  • 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, 7.24a and 7.25a. 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 VII. Venting D. Design Requirements Unique to Split Vent Systems (continued) Table 7.21: Summary of Split Vent System Options (cont.) 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...
  • Page 37 VII. Venting D. Design Requirements Unique to Split Vent Systems (continued) Table 7.21: Summary of Split Vent System Options (cont.) Option # Illustrated in Figure 7.22 7.22 7.23, 7.24 7.23, 7.24 7.23, 7.24 7.23, 7.24 Pipe Vent Roof Roof Roof Roof Roof Roof...
  • Page 38 VII. Venting D. Design Requirements Unique to Split Vent Systems (continued) Table 7.21: Summary of Split Vent System Options (cont.) Option # Illustrated in Figure 7.23, 7.24 7.23, 7.24 7.25a Vent Roof Roof Roof Pipe Penetration Through Structure Intake Wall Wall Wall Centrotherm...
  • Page 39 VII. Venting D. Design Requirements Unique to Split Vent Systems (continued) FIRE STOP LISTED FOR USE WITH VENT SYSTEM PITCH 1/4" PER FT TOWARDS TRAP PVC AIR INTAKE PIPE Figure 7.22: Split Rigid Vent System (Vent Options 25-32) PVC AIR INTAKE PIPE Figure 7.23: Split Vent System (Flex in B-Vent Chase) Vent Options 33-38) 107672-03 - 5/18...
  • Page 40 VII. Venting D. Design Requirements Unique to Split Vent Systems (continued) EXHAUST NOTE: DURAVENT POLYPRO FLEX COMPONENTS SHOWN. PPs FLEX CLEAN, TIGHT UNUSED CHIMNEY DURAVENT POLYPRO OUTSIDE WALL VENT PIPE PVC ELBOW PVC AIR WITH RODENT INTAKE PIPE SCREEN 12" MIN BASE SUPPORT AND ELBOW FOR PPs FLEX PIPE...
  • Page 41 VII. Venting D. Design Requirements Unique to Split Vent Systems (continued) WITH CROWN 45° MAX BOILER CHIMNEY AND FOUNDATION ARE STRUCTURALLY SOUND WARNING Venting of Other Appliances (Or Fireplace) into Chase or Adjacent Flues Prohibited! BOILER Figure 7.24b: Flexible PP Masonry Chimney Chase Requirements 107672-03 - 5/18...
  • Page 42 VII. Venting D. Design Requirements Unique to Split Vent Systems (continued) Figure 7.25a: Split Vent Systems (SS Flex in Abandoned Masonry Chimney) (Vent Option 39) WARNING Venting of Other Appliances (Or Fireplace) into Chase Prohibited! Figure 7.25b: Flexible SS Masonry Chimney Chase Requirements 107672-03 - 5/18...

  • Page 43: 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. •...
  • Page 44 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. h.
  • Page 45 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 4. Installation of Vertical Fitting Terminals (Terminal Option H): a. See Figure 7.29 for the proper orientation of twin pipe vertical terminals. b.
  • Page 46 VII. Venting E. Assembly of CPVC/PVC Vent Systems (continued) 5. Installation of IPEX low profile vent terminal (Terminal Option B) - See Figure 7.30: a. Cut two holes in wall to accommodate the size PVC pipe being used. The distance between hole centers is 5.6”.
  • Page 47 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 107672-03 - 5/18...
  • Page 48 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 107672-03 - 5/18...
  • Page 49 VII. Venting E. Assembly of CPVC/PVC Vent Systems (continued) Figure 7.34: Installation of IPEX and DiversiTech Concentric Terminal Through Roof f. Slip the partially assembled terminal through the wall or ceiling from the inside and for horizontal installations orient so that the side outlet on the Wye is on or above the horizontal plane. g.

  • Page 50: 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 listed 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 7.36: Installation of Duravent PolyPro UV Resistant Single Wall Horizontal Terminal Figure 7.37: Installation of Duravent PolyPro UV Resistant Single Wall Vertical Terminal 107672-03 - 5/18...
  • 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 7.39) 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.
  • Page 54 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 107672-03 - 5/18...

  • Page 55: 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 56 VII. Venting G. Assembly of Selkirk Polyflue Vent Systems (continued) c. For each joint, verify that the gasket is evenly seated in the bell (female) end of the pipe. Lubricate this gasket with mild soapy water. Slide a Pipe Locking Band over the male end of the pipe to be joined as shown in Figure 7.41.
  • Page 57 VII. Venting G. Assembly of Selkirk Polyflue Vent Systems (continued) NOTICE The venting system must be free to expand and contract and supported in accordance with the installation instructions included by the original Polypropylene venting component manufacturer, Selkirk. Polypropylene pipe sections must be disengaged 1/8 to 1/4 in. (3mm to 6mm) per joint to allow for thermal expansion.
  • Page 58 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 107672-03 - 5/18...

  • Page 59: Assembly Of Centrotherm Innoflue Vent Systems

    VII. Venting H. Assembly of Centrotherm InnoFlue Vent Systems 1. This boiler has been listed 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 (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 61 VII. Venting H. Assembly of Centrotherm InnoFlue Vent Systems (continued) 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 107672-03 - 5/18...
  • Page 62 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: Assembly Of Stainless Steel Vent Systems

    This boiler has been listed for use with Duravent FasNSeal Flex Stainless Steel vent systems to be provided by the installer. WARNING Asphyxiation Hazard. Follow these instructions and the installation instructions included by the original stainless steel venting component manufacturer DuraVent. Failure to do so could cause products of combustion to enter the building, resulting in severe property damage, personal injury or death.
  • Page 64 VII. Venting I. Assembly of Stainless Steel Vent Systems (continued) c. Flexible stainless steel vent shall be installed in an UNUSED masonry chimney and supplying combustion air through a separate wall or roof combustion air terminal. The unused chimney flue must be structurally sound and in good repair.

  • Page 65: Condensate Trap And Drain

    VII. Venting J. Condensate Trap and Drain Line J. 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.

  • Page 66: Removing An Existing Boiler From Common Chimney

    VII. Venting K. Removing an Existing Boiler From a Common Chimney K. 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 67: 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.
  • Page 68 VIII. Gas Piping (continued) SUPPLY *MANUAL SHUT-OFF VALVE (FACTORY SUPPLIED - MUST GROUND BE INSTALLED WITHIN 6FT JOINT OF THE BOILER) UNION Figure 8.1: Gas Connection to Boiler Table 8.2: Minimum and Maximum Inlet Pressures Model Max. (Natural & LP) Min.

  • Page 69: 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 70: 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 9.9, using the side outlet Tee and other fittings provided. ASME Section IV currently requires that this relief water or stream will not create a hazard or cause property damage if the valve opens.
  • Page 71 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.

  • Page 72: Near Boiler Piping Design

    IX. System Piping (continued) 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 9.1 any time the boiler is firing. At flow rates below the minimum shown, the boiler’s flow switch and/or temperature rise limit function may prevent the boiler from firing.
  • Page 73 IX. System Piping (continued) 107672-03 - 5/18...
  • Page 74 IX. System Piping (continued) 107672-03 - 5/18...
  • Page 75 IX. System Piping (continued) 107672-03 - 5/18...
  • Page 76 IX. System Piping (continued) 107672-03 - 5/18...
  • Page 77 IX. System Piping (continued) Example – A 120MBH model is to be connected to a heating system as shown in Figure 9.6. A total of 20 ft of straight pipe will be installed between the boiler and the system loop. Count all fittings in the boiler loop (shaded in Figure 9.6): 3 90°...
  • Page 78 IX. System Piping (continued) 107672-03 - 5/18...
  • Page 79 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.
  • Page 80 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 107672-03 - 5/18...

  • Page 81: Piping For Special Situations

    IX. System Piping (continued) D. Piping for Special Situations System containing oxygen - Many hydronic systems contain enough dissolved oxygen to cause severe corrosion damage to a boiler. Some examples include: • Radiant systems that employ tubing without an oxygen barrier. •...

  • Page 82: 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 f the pump outputs are as follows: System Pump - Pumps water through the radiation. This pump is hydraulically sepa rated 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) Figure 10.2: High Voltage PCB Terminal Connections Figure 10.3: Low Voltage PCB Terminal Connections 107672-03 - 5/18...
  • Page 85 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) •...
  • Page 86 X. Wiring (continued) Figure 10.4: 4-20 mA EMS Field Wiring Figure 10.5: J3 Field Wiring 107672-03 - 5/18...
  • Page 87 X. Wiring (continued) Primary/Secondary Tee Close Nipple (Locate Header Sensor As Close As Possible To Downstream Tee) Sensor Clip Header Temperature Sensor (Honeywell 32003971-003) (U.S.B.C. P/N: 103104-01) Well Should Extend Into Header Flow As Far As Possible. Use Extension Only If Necessary. Honeywell Immersion Well Figure 10.6: Proper Installation of Header Sensor...
  • Page 88 X. Wiring (continued) Figure 10.7: Internal Ladder Diagram 107672-03 - 5/18...
  • Page 89 PAGE LEFT INTENTIONALLY BLANK. 107672-03 - 5/18...
  • Page 90 X. Wiring (continued) 107672-03 - 5/18...
  • Page 91 X. Wiring (continued) 107672-03 - 5/18...
  • Page 92 X. Wiring (continued) Table 10.7: Internal Wire Connection Markings Cross Reference Table WIRE NO. IN FIG. 10.7 WIRE MARKING WIRE NO. IN FIG 10.7 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 93 X. Wiring (continued) Figure 10.9: TACO SR504 or Equivalent Zone Panel Wiring Connection Diagram 107672-03 - 5/18...
  • Page 94 X. Wiring (continued) Figure 10.10: Sage Zone Control Circulator Panel Wiring Connection Diagram 107672-03 - 5/18...

  • Page 95: 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 96 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.
  • Page 97 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 The boiler should attempt to fire approximately 30 seconds after a call for heat appears. With the upper front cover removed from the boiler, this try for ignition will appear as an audible spark (lasting approximately 4 seconds) and an audible click from the gas valve.
  • Page 98 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 107672-03 - 5/18...
  • Page 99 XI. Start-Up and Checkout (continued) Figure 11.4: Gas Valve Detail (80B-180B) Figure 11.5: Gas Valve Detail (180M) 107672-03 - 5/18...
  • Page 100 XI. Start-Up and Checkout (continued) WARNING Do not attempt to operate this boiler on LP gas without converting it using the proper conversion kit. • Do not attempt to convert this boiler to LP gas without the use of a combustion analyzer. •...
  • Page 101 XI. Start-Up and Checkout (continued) WARNING Asphyxiation Hazard. Use combustion analyzer for all gas valve adjustments. Low fire offset screw is very sensitive. Adjust offset no more than 1/8 turn before checking combustion with analyzer. Maximum total adjustment ± 1 turn. Failure to follow these instructions could result in death, serious injury or substantial property damage.
  • Page 102 XI. Start-Up and Checkout (continued) Perform a check of the ignition safety shut-off device. With the burner firing, carefully unplug the orange flame rod wire at the flame rod using a pair of insulated pliers (Figure 11.1). The burner should shut off immediately.
  • Page 103 XI. Start-Up and Checkout (continued) Lighting and Operating Instructions 107672-03 - 5/18...

  • Page 104: 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.
  • Page 105 XII. Operation (continued) 7. Warm Weather Shutdown (WWSD) Table 12.1: Order of Priority Some boilers are used primarily for heating Status Screen Priority Boiler Responding to: buildings, and the boilers can be automatically Display shutdown when the outdoor air temperature is Sequencer The boiler is connected to the peer- warm.
  • Page 106 XII. Operation (continued) Setpoint or is automatically adjusted as Outdoor control and high limit features. The control monitors a dual element temperature sensor that is mounted Air Reset in the supply water manifold and provides UL353 5. Outdoor Air Reset and UL1998 internal safety algorithms.
  • Page 107 XII. Operation (continued) indication is provided. Additionally, the control D. Multiple Boiler Control Sequencer monitors an air proving switch. During the boiler 1. “Plug & Play” Multiple Boiler Control start sequence the control requires the air proving Sequencer switch to be in the “open” position before the When multiple boilers are installed, the Control’s blower starts and in the “closed”...
  • Page 108 XII. Operation (continued) 5. Customized Sequences 11. Advanced Boiler Sequencing Normally, boilers are started and stopped in After there is a Call For Heat input, both header numerical order. However, custom sequences water temperature and boiler firing rate percent may be established to optimize the heat delivery. are used to start and stop the networked boilers.
  • Page 109 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 110 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.
  • Page 111 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”...
  • Page 112 XII. Operation E. Boiler Sequence Of Operation (continued) 3. Status Screens (continued) Bargraph Screen The bargraph screen presents measured values for easy comparison. An information screen provides monitoring of “Rate Demand To Fan” and “Fan Speed Feedback”. These additional monitoring points are provided to help monitor blower performance.
  • Page 113 XII. Operation E. Boiler Sequence Of Operation (continued) 3. Status Screens (continued) Zone Control Status Screens Active zones are shown by bold Zone Control Status & underlined numbers. Press the Zone Control Status zone panel to view zone cycle press <...
  • Page 114 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.
  • Page 115 XII. Operation (continued) F. Changing Adjustable Parameters 1. Entering Adjust Mode Adjust Mode The Control is factory programmed Warning! Improper settings or service to include basic modulating boiler create risk of property functionality. These settings are For Service Contact: damage, injury or death. CONTRACTOR NAME password protected to discourage Contractor...
  • Page 116 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...
  • Page 117 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 118 XII. Operation F. Changing Adjustable Parameters (continued) Table 12.10: Parameters Changed Using the Boiler Type Parameter Selections: Control Service Part Kit Part Number 107877-01 Altitude 0-2000 Ft. Configuration K2WT-080B-02-N K2WT-100B-02-N K2WT-120B-02-N K2WT-150B-02-N K2WT-180B-02-N K2WT-180M-02-N Maximum Heat Rate (RPM) 7100 7400 7300 7900 8100...
  • Page 119 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 120 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 121 XII. Operation F. Changing Adjustable Parameters (continued) Example Pump Parameter selections: Single boiler with no Indirect Water Heater From System Hydraulic Separator Relief May Be Substituted Valve For Tees Close Nipple (Locate Header Sensor As Close As Possible Y-Strainer System To Downstream Tee) (Recommended) Parameter Selection:...
  • Page 122 XII. Operation F. Changing Adjustable Parameters (continued) Example Pump Parameter selections (continued): Single Boiler with Supply Piped IWH, System and DHW Wired to Master From Parameter Selections: System System Pump = “Central Heat, Hydraulic Separator Relief Optional Priority” May Be Substituted Valve For Tees Close Nipple...
  • Page 123 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 124 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 125 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 126 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 127 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 IHW Tank Selected when boiler is piped to an indirect water heater. Combi Selected when a Combi Kit is attached to the boiler. Combi When selected, special parameters are entered to allow the required Combi rate Tank...
  • Page 128 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 129 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 130 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 131 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 132 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 133: Service And Maintenance

    XIII. Service and Maintenance Important Product Safety Information Refractory Ceramic Fiber Product WARNING The Service 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 134 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 135 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: a. Keep the area around the boiler free from combustible materials, gasoline and other flammable vapors and liquids.
  • Page 136 XIII. Service and Maintenance (continued) When disconnecting flexible gas line; Flexible Gas Line Place a backup wrench on this nut to Connection prevent damage to the gas valve. Figure 13.1: Disconnecting Flexible Gas Line Figure 13.2: Flame Ionization Electrode and Ignition Electrode Location 107672-03 - 5/18...
  • Page 137 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).
  • Page 138 XIII. Service and Maintenance (continued) Figure 13.3: Ignition Electrode Gap Figure 13.4: Condensate Trap Exploded Parts View 107672-03 - 5/18...
  • Page 139 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. s. Replace any wiring which has been disconnected. Inspect the hydronic system.

  • Page 140: 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 141 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 142 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 143 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. The boiler will automatically restart once the condition that caused the lockout is corrected.
  • Page 144 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 or dirty. shorted to ground •...
  • Page 145 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. Once the condition that caused the lockout is corrected, the boiler will need to be manually reset using the Reset button on the “Active Fault”...

  • Page 146: Service Parts

    XV. Service Parts All K2WT™ Series Service 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 service parts, please contact U.S. Boiler Customer Service at (717) 481-8400 or Fax (717) 481-8408.
  • Page 147 XV. Service Parts (continued) Part Number Key No. Description 180B 180M 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 Bare Heat Exchanger Flue Outlet Gasket 105882-01 Flue Temperature Sensor...
  • Page 148 XV. Service Parts (continued) 107672-03 - 5/18...
  • Page 149 XV. Service Parts (continued) Part Number Key No. Description 180B 180M 27, 28, 29, 36 Gas Train Assembly, Natural Gas 107869-01 107866-01 107867-01 27, 28, 29, 36 Gas Train Assembly, LP Gas 107868-01 107870-01 107871-01 Not Shown LP Gas Conversion Kit 107873-01 107874-01 107875-01 108101-01...
  • Page 150 XV. Service Parts (continued) Part Number Key No. Description Condensate Trap (includes gasket, 51, 52, 53 105851-01 bracket and trap ball) Silicone Tubing (includes 3/16” and 54, 55, 56, 57, 3/4” tubing, spring clamp, and vent 105855-01 fitting) Sump Pressure Switch 107878-01 107672-03 - 5/18...
  • Page 151 XV. Service Parts (continued) Part Number Key No. Description 67, 68, Low Voltage Printed Circuit Board (PCB) 105853-01 69, 73 (includes Low Voltage PCB and hardware) High Voltage Printed Circuit Board (PCB) 67, 70, (includes Line Voltage PCB, insulator, 105852-01 71, 72, 73 gasket and hardware) 8-18 x 1/2”...
  • Page 152 XV. Service Parts (continued) 107672-03 - 5/18...
  • Page 153 XV. Service Parts (continued) Part Number (Qty) Description Transformer 106034-01 Sage 2.3 Boiler Control 107877-01 77, 78, Control Door Parts 107872-01 82,97 8-18 x 1/2” Self Tapping Screw Obtain locally Programmable Display GT02L 107864-03 8-18 x 1/2” Self Tapping Screw Obtain locally 107672-03 - 5/18...
  • Page 154 XV. Service Parts (continued) 107672-03 - 5/18...
  • Page 155 XV. Service Parts (continued) Part Number Key No. Description 86, 90 Wall Mounting Brackets 102989-01 5/16 x 2” Lag Screw Obtain locally 93, 99, 100, 101, Jacket Set, Painted Panels 107902-01 107903-01 3” PVC Intake Coupling with Locknut 105848-01 Vent Connector (includes connector, gasket, and 107034-01 hardware) 8-18 x 1/2”...
  • Page 156 XV. Service Parts (continued) Part Number Description 1”NPT X 2-1/2” Nipple Obtain locally 1” NPT Tee Obtain locally 3/4” NPT Boiler Drain Valve Obtain locally 1”NPT x 2” Nipple Obtain locally 1” NPT Tee with Side Outlet 107895-01 1” x 1/4” NPT Hex Reducing Bushing Obtain locally Temperature &...
  • Page 157 XV. Service Parts (continued) Part Number Key No. Description Low Voltage / Communication 107876-01 High Voltage Harness 105868-01 Trap/Flame, Trap/Ground, 132, 133, Circulator Pigtail (includes wire 105870-01 harness) Ignition Cable Harness 105907-01 LWCO Jumper 105908-01 shown Outdoor Temperature Sensor 102946-01 Shown 107672-03 - 5/18...

  • Page 158: Appendix A: Instruction For High Altitude Installation Above 2,000 Ft

    Appendix A: Instructions for High Altitude Installations Above 2000 ft. WARNING If installing K2WT-080B or K2WT-180B, do not attempt to convert K2WT-080B for use with LP at altitudes above 2000 ft. Also, do not attempt to install K2WT-180B at altitudes above 2000ft. K2WT- 180M shall be installed at altitudes ranging from 2001-10100ft.
  • Page 159 Appendix A - (continued) Table A1: K2WT Altitude Adjustments for Natural Gas (Above 2000 ft. only) Measured %CO Model No. 2001-6000 ft. 6001-7800 ft. 7801-10,100 ft. Max. CO Air Free Range Target Range Target Range Target K2WT-080B 8.4-8.7 8.6-8.9 8.6-8.9 K2WT-100B 8.8-9.1 8.6-8.9...
  • Page 160 Appendix A - (continued) Table A2: K2WT Altitudes Derates for Natural Gas Approximate Derate per 1000 ft. Model No. 2001-6000 ft. 6001-7800 ft. 7801-10,100 ft. K2WT-080B 0.9% 4.0% 4.0% K2WT-100B 1.9% 2.6% 2.7% K2WT-120B 1.2% 1.8% 2.4% K2WT-150B 2.6% 2.9% 3.1% K2WT-180B Not Permitted...

  • Page 161: Appendix B: Special Requirements For Side Wall Vented Appliances In The Commonwealth Of Massachusetts

    Appendix B: 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 162 Appendix B - (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 168 U.S. Boiler Company, Inc. P.O. Box 3020 Lancaster, PA 17604 1-888-432-8887 www.usboiler.net 107672-03 - 5/18...

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