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OPEraTing inSTrUCTiOnS
FOr
K2™
CONDENSING HIGH EFFICIENCY
DIRECT VENT
GAS - FIRED HOT WATER BOILER
9700609
as an EnErgY STar
Partner, U.S. Boiler Company has determined that the K2™ Series meets the EnErgY
®
STar
guidelines for energy efficiency established by the United States Environmental Protection Agency (EPA).
®
Warning:
Improper installation, adjustment, alteration, service or maintenance can cause property damage,
injury, or loss of life. For assistance or additional information, consult a qualified installer, service agency or the
gas supplier. This boiler requires a special venting system. Read these instructions carefully before installing.
Price - $5.00
1
105337-02 - 9/14
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Table of Contents
Related Manuals for Energy Star K2
Summary of Contents for Energy Star K2
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Page 1: Operating Instructions
DIRECT VENT GAS - FIRED HOT WATER BOILER 9700609 as an EnErgY STar Partner, U.S. Boiler Company has determined that the K2™ 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 K2™ 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 Installation is not complete unless a safety relief valve is installed into the tapping located on left side of appliance or the supply piping. - See the Water Piping and Trim Section of the K2 installation manual for details.
- Page 4 Table of Contents Operation Troubleshooting 105337-02 - 9/14...
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Page 5: Operation
i. Operation (A. Overview) A. Overview 6. Warm Weather Shutdown (WWSD) Some boilers are used primarily for heating buildings, 1. Sage 2.1 Controller and the boilers can be automatically shutdown when The Sage 2.1 Controller (Control) contains features and the outdoor air temperature is warm. When outside air capabilities which help improve heating system operation, temperature is above the WWSD setpoint, this function and efficiency. - Page 6 i. Operation B. Supply Water Temperature Regulation (contineud) B. Supply Water Temperature Regulation properly matched to heating needs there is minimal chance of room air temperature overshoot. Excessive heat is 1. Priority Demand not sent to the room heating elements by “overheated” The Control accepts a call for heat (demand) from (supply water temperature maintained too high a setting) multiple places and responds according to it’s “Priority”.
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Page 7: Boiler Protection Features
i. Operation C. Boiler Protection Features (continued) C. Boiler Protection Features 5. Boiler Mounted Limit Devices The control monitors individual limit devices: flow 1. Supply Water Temperature High Limit switch, thermal fuse and sump pressure switch. If any of The control is equipped with internal operating these limits open the boiler will shut down and an open control and high limit features. -
Page 8: Multiple Boiler Control Sequencer
i. Operation D. Multiple Boiler Control Sequencer (continued) 6. Multiple Demands D. Multiple Boiler Control Sequencer The Sequence Master responds to Central Heat, DHW 1. “Plug & Play” Multiple Boiler Control Sequencer and frost protection demands similar to the stand alone When multiple boilers are installed, the Control’s boiler. -
Page 9: Normal Operation
X. Operation E. Boiler Sequence Of Operation (continued) E. Multiple Boiler Control Sequencer 1. Normal Operation Table 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 10: Using The Display
i. 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. Navigation features are shown below. 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 11: Viewing Boiler Status
i. Operation F. Viewing Boiler Status (continued) F. Viewing Boiler Status 1. 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 12: Detail Screens
i. Operation F. Viewing Boiler Status (continued) 1. Status Screens (continued) Data Logging Cycles and Hours Real time graphic trends allow users to observe process Boiler cycles and hours are used to monitor the changes over time providing valuable diagnostic boilers overall compatibility to the heating load. - Page 13 i. Operation F. Viewing Boiler Status (continued) 3. Multiple Boiler Sequencer Screens available When the Sequence Master is enabled the following screens are 105337-02 - 9/14...
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Page 14: Changing Adjustable Parameters
i. Operation G. Changing Adjustable Parameters (continued) G. Changing Adjustable Parameters 1. Entering Adjust Mode The Control is factory programmed to include basic modulating boiler functionality. These settings are password protected to discourage unauthorized or accidental changes to settings. User login is required to view or adjust these settings: Press the “Adjust”... - Page 15 i. Operation G. Changing Adjustable Parameters (continued) 2. Adjusting Parameters (continued) 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 Modulation Setup...
- Page 16 This is the blower speed during ignition and flame stabilization periods. Table 4: Parameters Changed Using the Boiler Type Parameter Selections: Control repair Part P/N 105439-01 altitude 0 - 2000 Ft. Boiler Type K2-80-02 K2-100-02 K2-120-02 K2-150-02 K2-180-02 Maximum Modulation Rate (RPM) 5100...
- Page 17 i. Operation G. Changing Adjustable Parameters (continued) “Press” Pump Setup 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, Never: Pump is disabled and not shown on status screen.
- Page 18 i. Operation G. Changing Adjustable Parameters (continued) Example Pump Parameter selections (continued): Single boiler Indirect Water Heater (IWH)Piped to Primary, Optional Domestic Hot Water Priority. Parameter Selections: System Pump = “Central Heat, Optional Priority” Boiler Pump = “any demand” DHW Pump = “Primary Loop Piped IWH” DHW Priority Enable is optional Explanation: This piping arrangement permits the...
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Page 19: Wiring Locations
i. Operation G. 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 20 i. Operation G. Changing Adjustable Parameters (continued) Contractor Setup “Press” button to access the following parameters: Contractor name For Service Contact: Bill Smith Press box to input contractor information. > < Bill Smith 12 Victory Lane Plainview, New York Save 516 123-4567 Press SAVE button to store revisions.
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Page 21: Factory Setting
i. Operation G. Changing Adjustable Parameters (continued) Central “Press” button to access the following parameters: Heat 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 Thermostat “Sleep”... - Page 22 i. Operation G. Changing Adjustable Parameters (continued) Domestic “Press” button to access the following parameters: Hot Water Factory Range / Choices Parameter and Description Setting Domestic Hot Water Setpoint 170°F 60°F to 190°F The Domestic Hot Water (DHW) Setpoint parameter is used to create a minimum boiler water (76.7°C) (16°C to 87.8°C) temperature setpoint that is used when DHW heat demand is “on”.
- Page 23 i. Operation G. Changing Adjustable Parameters (continued) Outdoor “Press” button to access the following parameters: Reset Factory Range / Choices Parameter and Description Setting 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 2.
- Page 24 i. Operation G. Changing Adjustable Parameters (continued) Central Heat Setpoint Boost Maximum Off Point Low Outside Air Temp = Central Heat Setpoint =180 F & 0 F minus Diff Above 10 F Default Boost Outdoor Air Reset Setpoint (Shown with thin lines, typical) TOD Setback Setpoint (Reset setpoint increased by 10 F every Default = 170 F...
- Page 25 i. Operation G. 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 Local, demand directly without using the internal setpoint.
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Page 26: Troubleshooting
II. 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 27 II. Troubleshooting (contined) C. Help Screen Faults indication Condition Possible Cause This alarm is active if the slave boiler has lost communication with the Sequence Master. Check the following: Sequencer - RJ 45 peer-to-peer network disconnected Sequencer Setup Setup - Sequencer Master was Enabled and then Disabled Fault - Master’s Boiler has been powered down.
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Page 28: Lockout Condition
Gas pressure under minimum value shown on rating plate. • Gas line not completely purged of air. • Defective Electrode. Models K2-080 through K2-180 - flame • Loose burner ground connection. failure after 5 tries to restart. • Defective Ignition Cable. - Page 29 Plugged drain line in trap. • Inadequate boiler water flow. Verify that circulator is operating and that Temperature rise between supply and return circulator and piping are sized per K2 Installation Instructions Manual, DT inlet/outlet high is too high. Water Piping and Trim Section.
- Page 30 • Gas pressure under minimum value shown on rating plate. • Gas line not completely purged of air. • Defective Electrode. Models K2-080 through K2-180 • Loose burner ground connection. Ignition failure Flame failure after 1 try to restart. •...
- Page 31 105337-02 - 9/14...
- Page 32 U.S. Boiler Company, Inc. P.O. Box 3020 Lancaster, PA 17604 1-888-432-8887 www.usboiler.net 105337-02 - 9/14...
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