Page 1 INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS FOR APEX™ CONDENSING HIGH EFFICIENCY DIRECT VENT GAS - FIRED HOT WATER BOILER 9700609 WARNING: Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury, or loss of life. For assistance or additional information, consult a qualifi ed installer, service agency or the gas supplier.
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 Apex™ 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 Special Installation Requirements for Massachusetts A. For all sidewall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes and where the sidewall exhaust vent termination is less than seven (7) feet above grade, the following requirements shall be satisfied: 1.
Page 4: Table Of Contents
TABLE OF CONTENTS Product Description, Specifications and Dimensional Data...... Unpacking Boiler..................10 III. Pre-Installation and Boiler Mounting............11 Venting...................... A. General Guidelines................15 B. CPVC/PVC Venting................20 C. Polypropylene Venting................. 26 D. Stainless Steel Venting................ 29 E. Removing the Existing Boiler............... 32 F.
Page 5: Product Description, Specifications And Dimensional Data
I. Product Description, Specifications and Dimensional Data Apex Series boilers are condensing high efficiency gas-fired stamped per Section IV ‘Heating Boilers’ of ASME Boiler and Pressure Vessel Code, which provide a maximum heat direct vent hot water boilers designed for use in forced hot...
Page 10: Unpacking Boiler
2.5% for each 1000 ft. above sea level. Net AHRI Water Ratings based on allowance of 1.15. Consult manufacturer before selecting boiler for installations having unusual piping and pickup requirements, such as intermittent system operation, extensive piping systems, etc.
Page 11: Pre-Installation And Boiler Mounting
G. General. for installation on combustible flooring. Do not install boiler on carpeting. 1. Apex boilers are intended for installations in an area with a floor drain, or in a suitable drain pan to C. Provide clearance between boiler jacket and...
Page 12 III. Pre-Installation and Boiler Mounting G. General (continued) 4. Boiler Installation: * Note: a. For basement installation provide a solid level base such as concrete where floor is not level or When boiler is vented vertically, the minimum where water may be encountered on the floor clearance from the rear of the jacket is increased around boiler.
Page 13 12 Attachment Bracket Placement”. in. (300 mm) horizontally and 3 ft. (900 mm) c. Apex boiler left and right side panels have a vertically from each other in order to prevent series of dimples at panel top and bottom. These combustion air contamination.
Page 14 III. Pre-Installation and Boiler Mounting G. General (continued) b. Gas Piping - Follow instructions in Section piping selection/sizing based on combined heating capacity and/or gross output of the VII “Gas Piping” of the manual for sizing selected stackable boiler combination. Follow and installation of an individual boiler.
Page 15: Venting
Do not exceed maximum vent/combustion air lengths listed in Table 5. Vent/combustion air b. The Apex is a Direct Vent (sealed combustion) length restrictions are based on equivalent length boiler. Combustion air must be supplied directly of vent/combustion air pipe (total length of to the burner enclosure from outdoors and flue straight pipe plus equivalent length of fittings).
Page 16: Combustion Air
IV. Venting A. General Guidelines (continued) Table 4: Vent/Combustion Air System Options Approved Direct Vent Component Orientation Termination Description Figures Part Vent System Material Table The system includes separate CPVC vent Standard pipe and PVC air intake pipe terminating 4, 5A, 5B (through sidewall) through sidewall with individual 9 through 13...
Page 17 IV. Venting A. General Guidelines (continued) Figure 4: Location of Vent Terminal Relative to Windows, Doors, Grades, Overhangs, Meters and Forced Air Inlets - Two-Pipe System Vent Terminal (Shown), Two-Pipe System Air Intake Terminal (Not Shown) Table 6A: Vent System and Combustion Air System Components Equivalent Length vs.
Page 18 IV. Venting A. General Guidelines (continued) Table 6B: Vent/Combustion Air Equivalent Length Calculation Work Sheet Combustion Air Vent 90° Elbow(s) (Installer Supplied) 90° Elbow(s) (CPVC Supplied with Boiler) Subtotal, Subtotal, Quantity Equivalent Quantity Equivalent Length, Nominal Diameter Equivalent Nominal Diameter Equivalent (Pc) Length, per Pc...
Page 19 IV. Venting A. General Guidelines (continued) Space centerlines of vent and combustion air terminals minimum 12 in. (300 mm) apart. More than 12 in. (300 mm) spacing is recommended. ii. If possible, locate vent and combustion air terminals on the same wall to prevent nuisance shutdowns.
Page 20: Cpvc/Pvc Venting
IV. Venting A. General Guidelines - B. CPVC/PVC Venting (continued) spacing is recommended to avoid frost damage to building surfaces where vent terminations are placed. q. For multiple boiler installations with vertical roof terminals, maintain minimum 12 in. (300 mm) horizontal distance between adjacent boiler vent terminals.
Page 21 IV. Venting B. CPVC/PVC Venting (continued) NOTICE a. Position the CPVC/PVC vent connector and gasket onto boiler rear panel and insert vent Do not exceed maximum vent/combustion connector inner stainless steel vent pipe into heat air system length. Refer to “2. Vent/ exchanger vent outlet.
Page 22 IV. Venting B. CPVC/PVC Venting (continued) Table 7C: CPVC/PVC Vent & Air Intake Components (Installer Provided) required for Optional Vertical (Roof) Termination Quantity Vent Components APX425 & APX525 APX625, APX725 & APX825 Vertical (Roof) Termination, 4 in. Vertical (Roof) Termination, 6 in. Schedule 40 PVC Coupler Schedule 40 PVC 90°...
Page 23 IV. Venting B. CPVC/PVC Venting (continued) Figure 10: Near-Boiler Vent/Combustion Air Piping Models APX625, APX725, and APX825 f. Clean all vent and combustion air pipe joints only: 6 in. x 6 in. two-pipe connector does not with primer and secure with transition cement have factory installed internal sealing gaskets at (4-oz.
Page 24 IV. Venting B. CPVC/PVC Venting (continued) Table 8: Expansion Loop Lengths Length of Loop Length Nominal Straight Run “L” Pipe Dia. (In.) 1520 1880 2159 2413 2642 1850 2290 Figure 11: CPVC/PVC Expansion Loop and Offset 2620 2950 3230 Vent Piping Running PVC vent pipe inside Enclosures and through Walls: •...
Page 25 IV. Venting B. CPVC/PVC Venting (continued) • When thimble is not used for non- combustible wall, size and cut wall opening such that a minimal clearance is obtained and to allow easy insertion of vent pipe. • Apply sealant between vent pipe and thimble or wall opening to provide Figure 13: Rodent Screen Installation weather-tight seal.
Page 26: Polypropylene Venting
IV. Venting B. CPVC/PVC Venting - C. Polypropylene Venting (continued) Sealant or equivalent between vent pipe and storm collar to provide WARNING weather-tight seal. • Install rodent screen and vent terminal Asphyxiation Hazard. Follow these (supplied with boiler). See Figure 13 for instructions and the installation instructions appropriate configuration.
Page 27 IV. Venting C. Polypropylene Venting ii. Centrotherm Eco Systems InnoFlue SW f. Do not install PVC to PP adapter at the lower Rigid Vent and Flex Flexible Vent comply combustion air supply port of the two-pipe vent with the requirements of UL 1738 ‘Standard system connector when using PVC pipe for for Safety for Venting Systems’...
Page 28 When there is a conflict between flexible is 20% greater than from rigid pipe. Multiply polypropylene pipe (liner) manufacturer measured flexible polypropylene liner length by installation instructions and Apex boiler 1.2 to obtain equivalent length. Installation, Operating and Service Instructions, Maximum equivalent length of flexible the more restrictive instructions shall govern.
Page 29: Stainless Steel Venting
IV. Venting C. Polypropylene Venting - D. Stainless Steel Venting (continued) Venting of Other Appliances (or Fireplace) into Chase or Adjacent Flues Prohibited! Figure 15: Flexible Vent in Masonry Chimney with Separate Combustion Air Intake D. Stainless Steel Venting NOTICE WARNING Do not exceed maximum vent/combustion Asphyxiation Hazard.
Page 30 IV. Venting D. Stainless Steel Venting (continued) Table 11A: Thermal Solutions Vent System Components (Stainless Steel, 4 in. only) Part Numbers Vent System Equivalent APX425 and Component Length of Pipe APX525 4 In. Vent SS Vent Kit 102501-02 Horizontal Vent Terminal 8116313 (Included in Kit) Figure 16: Field Installation of Two-Pipe Vent...
Page 31 IV. Venting D. Stainless Steel Venting (continued) 3. System Assembly Vent Termination • Use a stainless steel tee in the upright position. WARNING Asphyxiation Hazard. Vent systems made NOTICE by Heat Fab, M&G / DuraVent and Z-Flex rely on gaskets for proper sealing. When these The joint between the terminal and the last piece of pipe must be outside of the building.
Page 32: Removing The Existing Boiler
IV. Venting D. Stainless Steel Venting - E. Removing the Existing Boiler - F. Multiple Boiler Installation Venting (continued) ii. Combustion Air Termination building. Turn on clothes dryers and any appliance not connected to the common venting system. • After penetrating wall, install a 90° Turn on any exhaust fans, such as range-hoods and elbow so that the elbow leg is in the up bathroom exhausts, so they will operate at maxi mum...
Page 33 IV. Venting F. Multiple Boiler Installation Venting (continued) et tous les ventilateurs d’extraction comme les d. For horizontal sidewall terminations, maintain hottes de cuisinière et les ventilateurs des salles de at least 12 in. (300 mm) minimum horizontal bain. S’assurer que ces ventilateurs fonctionnent distance between any adjacent individual boiler à...
Page 35: Condensate Disposal
V. Condensate Disposal A. Condensate Trap and Drain Line 1. All condensate which forms in the boiler or vent WARNING system collects in the sump under heat exchanger Asphyxiation Hazard. Failure to fill the and leaves the boiler through factory installed condensate trap with water prior to boiler start- condensate trap.
Page 36 V. Condensate Disposal (continued) Figure 18: Condensate Trap and Drain Line B. Condensate Neutralizer Installation 3. Limestone chips will get coated by neutral salts (product of chemical reaction between limestone 1. Some jurisdictions may require that the condensate and acidic condensate) and lose neutralizing be neutralized before being disposed of.
Page 37: Water Piping And Trim
19A “Factory Supplied Piping and Trim Trim Components Installation - APX425 and APX525”) Apex boilers have factory supplied Miscellaneous Parts a. Locate and remove ¾ in. NPT x close black Carton, which includes packaged flow switch with two nipple, ¾ in. NPT x 12 in. black nipple, ¾ in.
Page 38 VI. Water Piping and Trim A. Factory Supplied Piping and Trim (continued) e. Install drain valve into tee bottom outlet. n. Apply pipe dope to the switch-threaded brass- bushing end. Then, mount the switch threaded f. Locate and remove (2) 1½ in. NPT x 2 in. long end with the attached paddle into 1-1/2 in.
Page 39 VI. Water Piping and Trim A. Factory Supplied Piping and Trim (continued) f. For APX625, select paddle stamped “3”. b. Locate 3/4 in. NPT x 12 in. black nipple, 3/4 in. FPT x 1 in. FPT safety relief valve, and 3/4 g.
Page 40 VI. Water Piping and Trim A. Factory Supplied Piping and Trim (continued) h. Install temperature & pressure gauge into the tee b. Install close nipple into tee branch. Then, screw branch. the assembly into boiler left side ¾ in. front tapping, making sure tee run outlet is in vertical i.
Page 41 Minimum pressure in the boiler 2. Direct connection of Apex boiler to heating must be 20 psi (140 kPa). Proper operation of the Apex system, similar to a conventional boiler, is boiler requires that the water flow through the boiler...
Page 43 – The flow control valve prevents circulators will be required to properly install an flow through the system unless the circulator is Apex boiler. See Paragraph B above for information operating. Flow control valves are used to prevent on sizing the circulators.
Page 44 “Factory Supplied Piping and Trim Installation”. NOTICE The Apex boiler heat exchanger is made from stainless steel tubular coil having relatively narrow waterways. Once filled with water, it will be subject to the effects of corrosion. Failure to take the following precautions to minimize corrosion and heat exchanger waterways overheating could result in severe boiler damage.
Page 47 Apex boiler heat exchanger. Some examples include but not limited to: Table 15: Multiple Boiler Water Manifold Sizing •...
Page 48 VI. Water Piping and Trim E. Multiple Boiler Installation Water Piping (continued) Figure 22B: Isolation of the Boiler From Oxygenated Water with A Plate Heat Exchanger (IWH Piped Off System Header) E. Multiple Boiler Installation Water Piping - See 2. For installations where indirect domestic hot water heater is combined with space heating, Table 15 and Figures 22B 23A and 23B.
Page 51: Gas Piping
VII. Gas Piping 1. Allowable pressure drop from point of delivery to boiler. Maximum allowable system WARNING pressure is ½ psig (3.4 kPa). Actual point of delivery pressure may be less; contact gas supplier for Explosion Hazard. Failure to properly pipe gas additional information.
Page 52 VII. Gas Piping (continued) B. Connect boiler gas valve to gas supply For materials or conditions other than those listed above, refer to National Fuel Gas Code, ANSI Z223.1/ system. NFPA 54 or Natural Gas and Propane Installation Code, CAN/CSA B149.1, or size system using standard engineering methods acceptable to authority having jurisdiction.
Page 53 Mount the 1 in. NPT external gas shutoff valve onto the nipple threaded end outside of the jacket 3. Apex boilers have factory supplied left side panel. miscellaneous parts cartons, which include gas- h.
Page 54 (continued) 3. For the low and high gas pressure switches C. Pressure test. See Table 19 for Apex Min./Max. proper operation, the boiler inlet gas pressure must Pressure Ratings. The boiler and its gas connection be within the range shown in Table 19.
Page 55: Electrical
VIII. Electrical 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 Electrical Shock Hazard.
Page 56 • 10 – “Remote Firing Rate +” E. Flow Switch Wiring • 11 – “External Limit” Apex boilers include factory provided flow switch to • 12 – “External Limit” prevent boiler overheating. See Section VI, Water Piping and Trim for pertinent details.
Page 57 VIII. Electrical (continued) Figure 26: Ladder Diagram...
Page 60 VIII. Electrical (continued) Figure 28A: Modified Wiring For DHW Priority When Using Low Flow Circulator Piped Off System Header - Heating (with Central Heating Circulators) Plus Alternately Piped Indirect Water Heater...
Page 65 VIII. Electrical (continued) G. External Multiple Boiler Control System As an alternate to the Sage2.1 Control internal sequencer, the Sage2.1 Control also accepts an input from an external sequencer. Follow multiple boiler control system manufacturer (Honeywell, Tekmar, etc.) instructions to properly apply a multiple boiler control system.
Page 66 VIII. Electrical (continued) G. Multiple Boiler Operating Information (continued) Figure 33: RJ45 Splitter Installation Detail 1. Required Equipment and Setup (continued) d. Multiple Boiler Setup Step Description Comments Wire the header sensor to low voltage terminal strip terminals “Header sensor”. Install and wire the Header NOTE Sensor...
Page 67: System Start-Up
(in Btu per cubic foot) WARNING from gas supplier. Explosion Hazard. Asphyxiation Hazard. 2. Apex gas valves have inlet and outlet Electrical Shock Hazard. Start-up of this boiler pressure taps with built-in shut off screw. Turn should be undertaken only by trained and skilled each screw from fully closed position three to four personnel from a qualified service agency.
Page 68 IX. System Start-up (continued) Apex Series Operating Instructions Figure 34: Operating Instructions...
Page 69 Direct WARNING to ignite the main fuel directly from the Ignition ignition source. Asphyxiation Hazard. Each Apex Series boiler Normal boiler operation. Modulation rate is tested at the factory and adjustments to the Running depends on temperature and setpoint air fuel mixture are normally not necessary.
Page 70 IX. System Start-up (continued) Figure 35: Burner Flame Table 22: Typical Combustion Settings, throttle screw counter-clockwise in 1/4 turn LP Gas increments and checking the O (or CO ) after each adjustment. If boiler is equipped with 2 gas High Fire Low Fire Boiler valves, throttle screw adjustments must be done...
Page 71 8. If measured input is too high, reduce maximum Apex models APX425 and APX525 are factory shipped modulation fan speed (either central heat or as natural gas builds and can be field converted to domestic hot water, depending on source of call for LP gas.
Page 72 IX. System Start-up (continued) WARNING WARNING Asphyxiation Hazard. The throttle adjustments Explosion Hazard. Asphyxiation Hazard. shown in Table 23 are approximate. The This conversion should be performed by a final throttle setting must be found using a qualified service agency in accordance with the combustion analyzer.
Page 73 IX. System Start-up (continued) Table 24A: Approximate Throttle Screw 1. Fully close throttle by turning throttle screw Adjustment Values from Fully Closed clockwise until it fully stops. Position, Natural Gas 2. Open throttle screw counter-clockwise the Boiler Throttle Position (Number of Counter- number of full (360 degrees) and partial turns listed Model clockwise Turns from Fully Closed Position...
Page 74 IX. System Start-up (continued) T. Controls Startup Check List The Control is factory programmed with default parameters. Before operating the boiler, these parameters must be checked and adjusted as necessary to conform to the site requirements. Follow the steps below, making selections and adjustments as necessary to ensure optimal boiler operation.
Page 75: Operation
X. Operation A. Overview a heating boiler lower as the outside air temperature increases. 1. Sage 2.1 Controller 6. Warm Weather Shutdown (WWSD) The Sage 2.1 Controller (Control) contains features and capabilities which help improve heating system operation, Some boilers are used primarily for heating buildings, and efficiency.
Page 76: Supply Water Temperature Regulation
X. Operation B. Supply Water Temperature Regulation (continued) 11. Modbus Communication Interface 4. Outdoor Air Reset A factory configured RS485 Modbus interface is available If an outdoor temperature sensor is connected to the boiler for Energy Management System (EMS)monitoring when and Outdoor Reset is enabled, the Central Heat setpoint not used for Multiple Boiler Sequencer Peer-To-Peer will automatically adjust downwards as the outdoor...
Page 77: Boiler Protection Features
It control retries 1 time and then goes into hard lockout. is factory provided with Apex boilers and must be installed Manual reset is required to resume boiler operation. as part of near boiler piping (see Section VI ‘Water Piping 9.
Page 78: Multiple Boiler Control Sequencer
X. 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 79: Boiler Sequence Of Operation
X. Operation E. Boiler Sequence Of Operation (continued) E. Boiler Sequence of Operation 1. Normal Operation Table 27: Boiler Sequence of Operation Status Screen Display Description Boiler 1 Priority: 140 F Supply (burner Off, circulator(s) Off) Standby > 140 F <...
Page 80: Using The Display
X. 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 81: Viewing Boiler Status
X. 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 82: Detail Screens
X. Operation F. Viewing Boiler Status (continued) 1. Status Screens (continued) Pump Status/Cycles Heat Demand Central Heat On System On < > < > Domestic Hot Water Off Boiler On Sequence Master Off DHW Off Frost Protection Off Frost Protection On Exercise On Pumping is a major part of any hydronic system.
Page 83: Multiple Boiler Sequencer Screens
X. Operation F. Viewing Boiler Status (continued) 3. Multiple Boiler Sequencer Screens available: When the Sequence Master is enabled the following screens are The Sequencer Status screen is selected by “pressing” “Status” button from the “Home” screen when Sequence Master is enabled. Rate: Header: The rate % value is equal to the...
Page 84: Changing Adjustable Parameters
X. Operation G. Changing Adjustable Parameters (continued) G. Changing Adjustable Parameters Adjust 1. Entering Adjust Mode Active Fault The Control is factory programmed Warning! Only Qualified to include basic modulating boiler Technicians Should Adjust functionality. These settings are password Controls, Contact Your For Service Contact: protected to discourage unauthorized or Qualified Heating Professional...
Page 85 X. Operation G. Changing Adjustable Parameters (continued) 2. Adjusting Parameters (continued) From the “Home” screen select the Adjust button to access the adjustment mode screens shown below (if required, refer to the previous page to review how to enter Adjustment mode): System Modulation Setup...
Page 86 X. Operation G. 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 87 X. Operation G. Changing Adjustable Parameters (continued) “Press” button to access the following parameters: Pump Setup 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, Any Demand:...
Page 88 X. Operation G. Changing Adjustable Parameters (continued) Example Pump Parameter selections (continued): Single boiler Indirect Water Heater 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...
Page 89 X. 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 90 X. Operation G. Changing Adjustable Parameters (continued) Contractor “Press” Setup 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.
Page 91 X. Operation G. Changing Adjustable Parameters (continued) Central “Press” button to access the following parameters: Heat Factory Range / Choices Parameter and Description Setting 180°F 80°F to 190°F Central Heat Setpoint (82.2°C) (26.7°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 92 X. 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 40.
Page 93 X. 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 94 X. Operation G. Changing Adjustable Parameters (continued) Remote “Press” button to access the following parameters: 4-20mA 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.
Page 95: Service And Maintenance
XI. 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 96 XI. Service and Maintenance (continued) 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. Read and understand the entire manual before attempting installation, start-up operation, or service.
Page 97 XI. Service and Maintenance (continued) DANGER Explosion Hazard. Electrical Shock Hazard. Burn Hazard. This boiler uses flammable gas, high voltage electricity, moving parts, and very hot water under high pressure. Assure that all gas and electric power supplies are off and that the water temperature is cool before attempting any disassembly or service.
Page 98 XI. Service and Maintenance (continued) Inspect the condensate trap to verify it is open and free from debris. Inspect condensate line integrity between boiler and condensate neutralizer (if used), condensate CAUTION / ATTENTION neutralizer and the drain. Clean/repair if needed. Electrical Shock Hazard.
Page 99 For 2. System Freeze Protection: parts identification, refer to Section XIII “Repair Parts”. a. The following heating system freeze protection products are recommended for Apex boilers: 1. Condensate Overflow Switch Removal and Fernox™ Protector Alphi 11 (combined Replacement: antifreeze and inhibitor).
Page 100 XI. Service and Maintenance (continued) e. Using pliers, release spring clip securing the l. Restore power supply to boiler. Fill up the trap overflow switch to condensate trap body and remove (see Section V “Condensate Disposal”) and the switch. Note that the switch has factory applied verify the switch operation.
Page 101: Troubleshooting
XII. 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 102 XII. Troubleshooting (continued) 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 Sequencer - RJ 45 peer-to-peer network disconnected Setup Setup - Sequencer Master was Enabled and then Disabled Fault - Master’s Boiler has been powered down.
Page 103 XII. 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 104 XII. 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 106: Repair Parts
XIII. Repair Parts All Apex Repair Parts may be obtained through your local authorized Thermal Solutions representatives or outlets. Should you require assistance in locating a Thermal Solutions representative or outlet in your area, or have questions regarding the availability of Thermal Solutions products or repair...
Page 107 XIII. Repair Parts (continued) Heat Exchanger Components Part Number Description APX425 APX525 APX625 APX725 APX825 1A Air Vent Valve 101586-01 1B Supply/Return Water Temperature Sensor (2 per boiler) 101685-01 1C High Limit Water Temperature Sensor 101653-01 Replacement Rear Insulation Disc Kit (includes insulation, disc, thermal link switch and instructions) 104998-01 (Warning: Contains RCF)
Page 108 XIII. Repair Parts (continued) APX425 and APX525 Blower / Gas Train Components Part Number Description APX425 APX525 APX625 APX725 APX825 Replacement Blower Kit (includes blower, blower 104999-01 104999-02 104999-03 outlet gasket and hardware) Blower Outlet Gasket 101345-01 102614-01 103263-01 Natural Gas: Natural Gas: Blower Inlet Assembly (includes gas orifice, injector 105001-01...
Page 110 XIII. Repair Parts (continued) Condensate Trap and Related Components Part Number Description APX425 APX525 APX625 APX725 APX825 Replacement Condensate Trap Kit (includes trap, float switch, grommet, coupling, and 104704-01 105006-01 104704-01 clamps) Replacement Condensate Float Switch Kit 105005-01 (includes float switch and clamp) Spring Hose Clamp, 15/16 in.
Page 111 XIII. Repair Parts (continued) Control Components Part Number Description APX425 APX525 APX625 APX725 APX825 Natural Gas: 105008-02 Replacement Sage2.1 Control (programmed) 104472-01 104472-04 104472-04 LP Gas: 105008-01 Replacement Display 104779-01 (programmed, includes mounting hardware) Transformer 102516-01 103193-01 Upper Front panel 102778-01 Control Slide Out Tray 103336-01...
Page 113 XIII. Repair Parts (continued) Sheet Metal, APX425 and APX525 Part Number Description APX425 APX525 Replacement Left Side Panel Kit 105017-01 105017-02 (includes labels, access panels, grommets and header gaskets) Replacement Right Side Panel Kit 105018-01 105018-02 (includes labels, access panels and gaskets) Replacement Top Panel Kit (includes labels) 105019-01 105019-02...
Page 115 XIII. Repair Parts (continued) Sheet Metal, APX625, APX725 and APX825 Part Number Description APX625 APX725 APX825 Replacement Left Side Panel Kit 105017-03 105017-04 (includes labels, access panels, grommets and header gaskets) Replacement Right Side Panel Kit 105018-03 105018-04 (includes labels, access panels and gaskets) Replacement Top Panel Kit (includes labels) 105019-03 105019-04...
Page 116 XIII. Repair Parts (continued) Additional Components Part Number Description APX425 APX525 APX625 APX725 APX825 CSD-1 Kit (not shown, includes manual reset high limit, immersion well, gas pressure switches, and 104780-01 hardware) Gas Pressure Switch Assembly 102670-01 Low Gas Pressure Switch 102702-01 High Gas Pressure Switch 102703-01...
Page 117 XIII. Repair Parts (continued) Wiring Harnesses Part Number Description APX425 APX525 APX625 APX725 APX825 Complete Wiring Harness (includes 10A, 10B, 10C & 10D) 102701-02 10A Main (Low Voltage) Harness 103009-02 10B High Voltage Harness 103010-02 10C Blower Power Harness 103012-01 10D Communication Harness 103011-01 10E Igniter Harness...
Page 118: Appendix A - Figures
Figure 1A Apex - Model APX425 Figure 1B Apex - Model APX525 Figure 1C Apex - Models APX625 and APX725 Figure 1D Apex - Model APX825 Section III - Pre-Installation and Boiler Mounting Figure 2 Clearances To Combustible and Non-combustible Material...
Page 119 Appendix A - Figures (continued) Figure Page Description Number Number Section VII - Gas Piping Figure 24 Recommended Gas Piping Figure 25 Gas Inlet Pressure Tap and Pressure Switch Location Section VIII - Electrical Figure 26 Ladder Diagram Figure 27 58 &...
Page 120: Appendix B - Tables
Dimensions (See Figures 1A, 1B, 1C and 1D) Table 2 Ratings Section III - Pre-Installation and Boiler Mounting Table 3 Apex Boiler Model Stacking Combinations Section IV - Venting Table 4 Vent/Combustion Air System Options Table 5 Vent/Combustion Air Pipe Length – Two-Pipe Direct Vent System Options...
Page 121 Appendix B - Tables (continued) Table Page Description Number Number Section VIII - Electrical Table 20 Boiler Current Draw Section IX - System Start-Up Table 21 Typical Combustion Settings, Natural Gas Table 22 Typical Combustion Settings, LP Gas Table 23 Approximate Number of Clockwise Throttle Screw Turns for LP Conversion Table 24A Approximate Throttle Screw Adjustment Values from Fully Closed Position, Natural Gas...
Page 124 LIMITED WARRANTY FOR APEX COMMERCIAL GRADE BOILERS Stainless Steel Heat Exchangers and Parts/Accessories Subject to the terms and conditions set forth below, Thermal Solutions, Lancaster, Pennsylvania hereby extends the following limited warranties to the original owner of a commercial grade water boiler or Thermal Solutions supplied parts and/or accessories manufactured and shipped on or after January 1, 2014: ONE YEAR LIMITED WARRANTY ON COMMERCIAL GRADE BOILERS AND PARTS / ACCESSORIES SUPPLIED BY THERMAL SOLUTIONS.

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