U.S. Boiler Company K2 Installation Instructions Manual
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U.S. Boiler Company K2 Installation Instructions Manual

Condensing high efficiency direct vent gas-fired hot water boiler
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inSTaLLaTiOn 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).
®
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
105294-05 - 5/15

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Summary of Contents for U.S. Boiler Company K2

  • Page 1: Installation 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 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 4 Special Installation Requirements for Massachusetts A. For all sidewall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes and where the sidewall exhaust vent termination is less than seven (7) ft. above grade, the following requirements shall be satisfied: 1.
  • Page 5 WARNINGS FOR THE HOMEOWNER FOLLOW ALL INSTRUCTIONS and warnings unless alarms or other safeguards are in place to printed in this manual and posted on the boiler. prevent such damage MAINTAIN THE BOILER. To keep your boiler safe DO NOT BLOCK AIR FLOW into or around the and efficient, have a service technician maintain boiler.

  • Page 6: Table Of Contents

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

  • Page 7: I. Product Description

    i. Product Description This boiler is a stainless steel gas fired condensing boiler designed for use in forced hot water heating systems requiring supply water temperatures of 180°F or less. It is designed for installation on a wall. This boiler may be vented vertically or horizontally with combustion air supplied from outdoors.

  • Page 8: Iii. Before Installing

    Gas Connection Rating * Model* Input Input Volume Connection Capacity “A” Size (NPT) Weight (MBH) (MBH) (MBH) (gal.) Size (NPT) (MBH) (lb.) K2-080 0.36 17” 1” 1/2” K2-100 0.44 17” 1” 1/2” K2-120 0.53 17” 1” 1/2” K2-150 0.79 21”...

  • Page 9: Iv. Locating The Boiler

    iii. Before installing (continued) All boilers are shipped from the factory configured for use with natural gas. They may be converted for use with LP gas (“propane”) using a combustion analyzer in accordance with the instructions in Appendix A. DangEr •...
  • Page 10 IV. Locating the Boiler (continued) 105294-05 - 5/15...

  • Page 11: V. 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 12 V. Mounting The Boiler (continued) Figure 5.1 Wall Layout/Mounting Hole Location 105294-05 - 5/15...
  • Page 13 V. Mounting The Boiler (continued) Figure 5.2 Boiler Mounting Bracket Installation / Boiler Wall Mounting 105294-05 - 5/15...

  • Page 14: Vi. Air For Ventilation

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

  • Page 15: Vii. Venting

    VII. Venting Warning Asphyxiation Hazard. Failure to vent this boiler in accordance with these instructions could cause products of combustion to enter the building resulting in severe property damage, personal injury or death. Do not interchange vent systems or materials unless otherwise specified. The use of thermal insulation covering vent pipe and fittings is prohibited.
  • Page 16 VII. Venting A. Vent System Design (continued) Figure 7.0a: Horizontal Twin Pipe Figure 7.0b: Vertical Twin Pipe Figure 7.0c: Split Venting 105294-05 - 5/15...
  • Page 17 VII. Venting A. Vent System Design (continued) • DuraVent PolyPro - ULC S636 listed Polypropylene special gas vent system. Use of flex piping is not permitted. • Selkirk Polyflue - ULC S636 listed Polypropylene special gas vent system. • Centrotherm InnoFlue SW - ULC S636 listed Polypropylene special gas vent system. Use of flex piping is not permitted. Use PVC and/or CPVC for the air intake system.
  • Page 18 VII. Venting A. Vent System Design (continued) Minimum Vent and Air Intake Lengths - Observe the minimum vent lengths shown in Tables 7.1, 7.13 and 7.21. 5. Clearances to Combustibles - Maintain the following clearances from the vent system to combustible construction: •...
  • Page 19 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 20 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 105294-05 - 5/15...

  • Page 21: B. Design Requirements Unique To Horizontal Twin Pipe Venting Systems

    VII. Venting B. Design Requirements Unique to Horizontal Twin Pipe Venting Systems (continued) B. Design Requirements Unique to Horizontal Twin Pipe Venting Systems Table 7.5 summarizes all horizontal twin pipe vent options. Illustrations of horizontal twin pipe vent systems are shown in Figures 7.6 –...
  • Page 22 2” 3” 2” 3” 2” 3” Nominal Diameter Intake 2” 3” 2” 3” 2” 3” 2” 3” Min Equivalent Vent Length: K2-080 12” 12” 12” 12” 12” 12” 12” 12” K2-100 12” 12” 12” 12” 12” 12” 12” 12” K2-120 12”...
  • Page 23 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 24 VII. Venting B. Design Requirements Unique to Horizontal Twin Pipe Venting Systems (continued) Figure 7.7: Horizontal CPVC/PVC Venting with Low Profile Terminal, (Vent Options #1 & 2, Terminal Options B & C) Figure 7.8: Horizontal CPVC/PVC Venting with Concentric Vent Terminal, (Vent Options #1 &...
  • Page 25 VII. Venting B. Design Requirements Unique to Horizontal Twin Pipe Venting Systems (continued) Figure 7.9: Duravent PolyPro, Selkirk, Polyflue or Centrotherm InnoFlue Horizontal Venting (Vent Option #3 - 8, Terminal Option A) Figure 7.10: Duravent PolyPro Horizontal Venting with Concentric Terminal, (Vent Options #3 &...
  • Page 26 VII. Venting B. Design Requirements Unique to Horizontal Twin Pipe Venting Systems (continued) 105294-05 - 5/15...

  • Page 27: C. Design Requirements Unique To Vertical Venting Systems

    VII. Venting C. Design Requirements Unique to Vertical Venting Systems (continued) Figure 7.12: Snorkel Terminal Configuration (CPVC/PVC Vent Systems Only) C. Design Requirements Unique to Vertical Venting Systems Table 7.13a summarizes all vertical twin pipe vent options. Table 7.13.b summarizes vent options in which an abandoned B-vent chimney is used both as a chase for the vent pipe and as a conduit for combustion air.
  • Page 28 2” 3” 2” 3” 2” 3” Nominal Diameter Intake 2” 3” 2” 3” 2” 3” 2” 3” Min Equivalent Vent Length: K2-080 12” 12” 12” 12” 12” 12” 12” 12” K2-100 12” 12” 12” 12” 12” 12” 12” 12” Models K2-120 12”...
  • Page 29 2” 3” Nominal Diameter Intake 2” or 3” 3” 2” or 3” 3” Min B Vent ID 5” 6” 5” 6” Min Equivalent Vent Length: K2-080 36” 36” 36” 36” K2-100 36” 36” 36” 36” K2-120 36” 36” Models K2-150 Not Permitted 52”...
  • Page 30 VII. Venting C. Design Requirements Unique to Vertical Venting Systems (continued) Terminal Option J: DiversiTech Concentric Terminal (Acceptable for Vent Options 10 & 11) - This terminal is shown in Figure 7.16 and may be used with CPVC/PVC vent systems. See Part VII-E of this manual and the DiversiTech instructions provided with the terminal, for installation details.
  • Page 31 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 32 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) 105294-05 - 5/15...
  • Page 33 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 34 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) 105294-05 - 5/15...

  • Page 35: D. Design Requirements Unique To Split Vent Systems

    VII. Venting D. Design Requirements Unique to Split Vent Systems (continued) D. Design Requirements Unique to Split Vent Systems Table 7.21 summarizes all split vent options. Illustrations of split vent systems are shown in Figures 7.22, 7.23, and 7.24. In addition to the requirements in Part VII-A, observe the following design requirements: 1.
  • Page 36 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 37 THIS PAGE LEFT BLANK INTENTIONALLY 105294-05 - 5/15...
  • Page 38 2” 3” 2” 3” 2” 3” Nominal Diameter Intake 2” or 3” 3” 2” or 3” 3” 2” or 3” 3” Min Equivalent Vent Length: K2-080 48” 48” 48” 48” 48” 48” K2-100 48” 48” 48” 48” 48” 48” K2-120 48”...
  • Page 39 VII. Venting D. Design Requirements Unique to Split Vent Systems (continued) Table 7.21: Summary of Split Vent System Options (cont.) 7.22 7.22 7.23, 7.24 7.23, 7.24 7.23, 7.24 7.23, 7.24 7.23, 7.24 7.23, 7.24 Roof Roof Roof Roof Roof Roof Roof Roof Wall...
  • Page 40 VII. Venting D. Design Requirements Unique to Split Vent Systems (continued) Figure 7.22: Split Rigid Vent System (Vent Options 25-32) Figure 7.23: Split Vent System (Flex in B-Vent Chase) Vent Options 33-38) 105294-05 - 5/15...
  • Page 41 VII. Venting D. Design Requirements Unique to Split Vent Systems (continued) Figure 7.24: Split Vent System (Flex in Abandoned Masonry Chimney) (Vent Options 33-38) 105294-05 - 5/15...
  • Page 42 VII. Venting D. Design Requirements Unique to Split Vent Systems (continued) Venting of Other Appliances (Or Fireplace) into Chase or Adjacent Flues Prohibited! Figure 7.25: Masonry Chimney Chase Requirements 105294-05 - 5/15...

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

    VII. Venting E. Assembly of CPVC/PVC Vent Systems (continued) E. Assembly of CPVC/PVC Vent Systems Warning Asphyxiation Hazard. Failure to follow these instructions could cause products of combustion to enter the building, resulting in severe property damage, personal injury or death. Use all CPVC vent components (supplied with the boiler) for near-boiler vent piping before transitioning to Schedule 40 PVC pipe (ASTM 2665) components for remainder of vent system.
  • Page 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.
  • 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 105294-05 - 5/15...
  • Page 46 VII. Venting E. Assembly of CPVC/PVC Vent Systems (continued) 5. Installation of Vertical Fitting Terminals (Terminal Option H): a. See Figure 7.29 for the proper orientation of twin pipe vertical terminals. b. The coupling is used to secure the rodent screen to the end of the vent pipe. c.
  • Page 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 105294-05 - 5/15...
  • 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 105294-05 - 5/15...
  • Page 49 VII. Venting E. Assembly of CPVC/PVC Vent Systems (continued) Figure 7.34: Installation of IPEX and DiversiTech Concentric Terminal Through Roof b. For vertical installations, cut a hole in the roof large enough to clear the concentric terminal at the location of the terminal (see Part VII-C of this manual for permitted terminal locations).

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

    VII. Venting F. Assembly of DuraVent PolyPro Vent Systems (continued) F. Assembly of DuraVent PolyPro Vent Systems 1. This boiler has been approved for use with the DuraVent PolyPro single wall Polypropylene vent system to be provided by the installer. Warning Asphyxiation Hazard.
  • Page 51 VII. Venting F. Assembly of DuraVent PolyPro Vent Systems (continued) 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 105294-05 - 5/15...
  • 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 740: Installation of Duravent PolyPro Concentric Terminal Through Roof 105294-05 - 5/15...

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

    VII. Venting F. Assy of DuraVent PolyPro & G. Selkirk Polyflue Vent Systems (continued) Installations using PolyPro-flex (Vent Options 18,19,33,34): Warning asphyxiation Hazard. When using PolyPro flex, observe the following precautions: • PolyPro flex may be damaged by handling at low temperatures. Do not bend, uncoil, or attempt to install if it has been stored at a temperature below 42°F without allowing it to warm to a higher temperature first.
  • Page 56 VII. Venting G. Assembly of Selkirk Polyflue Vent Systems (continued) e. Support each pipe section as described in Polyflue manual at intervals not exceeding the following: Pipe size Horizontal Vertical 2” 30in 16ft 3” 39in 16ft nOTiCE Once a vent pipe is inserted into this adaptor, it is IMPOSSIBLE to remove it. Make sure the correct type of pipe is selected, and that it is of the correct length, before inserting it into the vent adaptor.
  • Page 57 VII. Venting G. Assembly of Selkirk Polyflue Vent Systems (continued) 6. Installations using flexible Polyflue (Vent Options 35,36): Warning Asphyxiation Hazard. When using Polyflue flex, observe the following precautions: • Polyflue flex may be damaged by handling at low temperatures. Do not bend, uncoil or attempt to install if it has been stored at a temperature below 42°F without allowing it to warm to a higher temperature first.
  • Page 58 VII. Venting G. Assembly of Selkirk Polyflue Vent Systems (continued) Figure 7.42: Installation of Selkirk Polyflue UV Resistant Single Wall Horizontal Terminal Figure 7.43: Installation of Selkirk Polyflue UV Resistant Single Wall Vertical Terminal 105294-05 - 5/15...

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

    VII. Venting H. Assembly of Centrotherm InnoFlue Vent Systems 1. This boiler has been approved for use with the Centrotherm InnoFlue single wall Polypropylene vent system to be provided by the installer. Warning Asphyxiation Hazard. Follow these instructions and the installation instructions included by the original Polypropylene venting component manufacturers, Centrotherm.
  • Page 60 VII. Venting H. Assembly of Centrotherm InnoFlue Vent Systems 3. Installation of Air Intake System - Start assembly of the PVC air intake system at the boiler. Assembly of the air intake system is done in the same manner as the vent system except as follows: a.
  • Page 61 VII. Venting H. Assembly of Centrotherm InnoFlue Vent Systems Figure 7.45: Installation of Centrotherm InnoFlue UV Stabilized Single Wall Horizontal Terminal Figure 7.46: Installation of Centrotherm InnoFlue UV Stabilized Single Wall Vertical Terminal 105294-05 - 5/15...
  • 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: I. Condensate Trap And Drain

    VII. Venting I. Condensate Trap and Drain Line (continued) I. Condensate Trap and Drain Line All condensate which forms in the boiler or vent system passes through the heat exchanger and out of a bottom drain port which is connected to the condensate trap with a hose. This trap allows condensate to drain from the heat exchanger while retaining flue gases in the boiler.
  • Page 64 VII. Venting J. Removing an Existing Boiler From a Common Chimney (continued) J. Removing an Existing Boiler From a Common Chimney This section only applies if this boiler is replacing an existing boiler that is being removed from a common chimney. In some cases, when an existing boiler is removed from a common chimney, the common venting system may be too large for the remaining appliances.

  • Page 65: Viii. Gas Piping

    VIII. Gas Piping Warning Explosion Hazard. Failure to properly pipe gas supply to boiler may result in improper operation or leaks of flammable gas. Gas supply to boiler and system must be absolutely shut off prior to installing or servicing boiler gas piping. Always assure gas piping is absolutely leak free and of the proper size and type for the connected load.
  • Page 66 It is very important that the gas line is properly purged by the gas supplier or utility company. Figure 8.1: gas Connection to Boiler Table 8.2: Minimum and Maximum Inlet Pressures Model Max. (Natural & LP) Min. (Natural) Min. (LP) K2-080 14.0” 2.5” 11.0” K2-100 14.0” 2.5”...

  • Page 67: Ix. System Piping

    IX. System Piping a. general System Piping Precautions Warning Failure to properly pipe boiler may result in improper operation and damage to boiler or structure. Install boiler so that the gas ignition system components are protected from water (dripping, spraying, rain, etc.) during boiler operation and service (circulator replacement, etc.).

  • Page 68: B. Near Boiler Piping Design

    Additional information on hydronic system design can be found in the I=B=R Guide RHH published by the Air-Conditioning, Heating and Refrigeration Institute (AHRI). Table 9.1: Flow Limitations Flow (GPM) Model Minimum Maximum K2-080 13.3 K2-100 13.3 K2-120 13.3 K2-150 13.3...
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  • Page 73 Equivalent Length of 30 ft or Less * Equivalent Length of 60 ft or Less * Approx. Flow Approx. Rise (°F) Approx. Flow Approx. Rise Boiler Model Boiler Model (GPM) (GPM) (°F) K2-080 K2-080 K2-100 K2-100 K2-120 K2-120 K2-150 12.9 K2-150 11.9 K2-180 12.9...
  • Page 74 105294-05 - 5/15...
  • Page 75 IX. System Piping (continued) Method 2: Direct Connection to Heating System (Generally NOT Recommended) In some relatively rare cases it may be possible to connect this boiler directly to the heating system as is done with conventional boilers (Figure 9.7). If this is done, the flow rate through the boiler will equal the flow rate through the system. The flow rate through the system must therefore always remain within the limits shown in Table 9.1.
  • Page 76 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 105294-05 - 5/15...

  • Page 77: C. Standard Piping Installation Requirements

    IX. System Piping (continued) C. Standard Piping Installation Requirements Observe the following requirements when installing the boiler piping: 1) Relief Valve (Required) – The relief valve is shipped loose and must be installed in the location shown in Figure 9.9, using the side outlet Tee and other fittings provided. ASME Section IV currently requires that this relief valve be installed above the heat exchanger as shown.
  • Page 78 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 79: D. Piping For Special Situations

    IX. System Piping (continued) D. Piping for Special Situations 1) Systems containing oxygen - Many hydronic systems contain enough dissolved oxygen to cause severe corrosion damage to a this boiler. Some examples include: • Radiant systems that employ tubing without an oxygen barrier. •...

  • Page 80: X. Wiring

    X. Wiring DangEr Electrical Shock Hazard. Positively assure all electrical connections are unpowered before attempting installation or service of electrical components or connections of the boiler or building. Lock out all electrical boxes with padlock once power is turned off. Warning All wiring and grounding must be done in accordance with the authority having jurisdiction or, in the absence of such requirements, with the National Electrical Code /NFPA 70).
  • Page 81 X. Wiring (continued) The use of the pump outputs are as follows: a) System Pump - Pumps water through the radiation. This pump is hydraulically separated from the boiler pump, either by closely spaced tees, or by a hydraulic separator. The system pump is always on when the system is responding to a call for CH.
  • Page 82 X. Wiring (continued) Figure 10.2: High Voltage PCB Terminal Connections Figure 10.3: Low Voltage PCB Terminal Connections 105294-05 - 5/15...
  • Page 83 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 84 X. Wiring (continued) Figure 10.4: Proper installation of Header Sensor 105294-05 - 5/15...
  • Page 85 X. Wiring (continued) 120V Line L  Boiler Control (R7910B) F1 (6.3A  Slow Blow)  DHW(N) DHW(L) P3‐10 J4‐2 J4‐3 P3‐4 DHW Pump P3‐11 J4‐4 J4‐5 L1‐1 L1‐2 P3‐1 Grounded to Boiler  Frame via PCB  Standoff/Mounting  Screw Boiler Pump SYS(L) SYS(N) P3‐7 J4‐6 J4‐7 P3‐6 System Pump Combustion Fan  Ground Screw  (120V Conn.) Bottom Panel P3‐9 P3‐2 Internal, non  replaceable 2 amp P3‐12 L2‐1...
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  • Page 88 X. Wiring (continued) Table 10.7: Internal Wire Connection Markings Cross Reference Table WIRE NO. IN FIG. 10.5 WIRE MARKING WIRE NO. IN FIG 10.5 WIRE MARKING 1 BK P3-10/J4-2 29 BK J2-3/FAN-4 2 BK P3-11/J4-4 30 BL J8-4/RET-1 3 BK P3-7/J4-6 31 B/G J8-5/RET-2...
  • Page 89 X. Wiring (continued) Figure 10.8: TACO SR504 or Equivalent Zone Panel Wiring Connection Diagram 105294-05 - 5/15...
  • Page 90 X. Wiring (continued) Figure 10.9: Sage Zone Control Circulator Panel Wiring Connection Diagram 105294-05 - 5/15...

  • Page 91: Xi. Start-Up And Checkout

    XI. Start-Up and Checkout Warning Completely read, understand and follow all instructions in this manual before attempting start-up. nOTiCE Safe lighting and other performance criteria were met with the gas train assembly provided on the boiler when the boiler underwent the test specified in 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 92 XI. Start-Up and Checkout (continued) DangEr Asphyxiation Hazard. Failure to properly convert this boiler for use on lp gas can cause unreliable operation at elevated carbon monoxide (CO) levels, resulting in personal injury or death. nOTiCE To minimize the risk of premature heat exchanger failure, observe the following water chemistry requirements: 1) Minimize the introduction of make-up water, dissolved oxygen, and contaminants into the boiler by following the installation guidelines shown in the “Water Quality and Boiler Water Additives Note”...
  • Page 93 XI. Start-Up and Checkout (continued) Figure 11.1: Location of Manual Air Vent 11) Start the boiler using the lighting instructions on page 97. With the boiler powered up, and with no call for heat, the display should look like Figure 11.2a. Once a call for heat is present, it will look like Figure 11.2b. 12) The boiler should attempt to fire approximately 30 seconds after a call for heat appears.
  • Page 94 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 105294-05 - 5/15...
  • Page 95 XI. Start-Up and Checkout (continued) Warning Asphyxiation Hazard. Each boiler is tested at the factory and adjustments to the air fuel mixture are normally not necessary when operating on natural gas at sea level. Consult the factory before attempting to make any such adjustments.
  • Page 96 Adjust the heating and indirect water heater thermostats to their final set points. Table 11.5: Typical Combustion Readings (Sea Level Only) Max. CO Model Fuel air Free K2-080 Natural Gas 8.9 - 9.3 4.6 - 5.3 K2-080 Propane 10.1 - 10.3 5.3 - 5.6...
  • Page 97 XI. Start-Up and Checkout (continued) Lighting and Operating Instructions 105294-05 - 5/15...
  • Page 98 Appendix A: Instructions for Conversion of this Boiler for use with LP Gas DangEr These instructions include a procedure for adjusting the air-fuel mixture on this boiler. This procedure requires a combustion analyzer to measure the CO2 (or Oxygen) and Carbon Monoxide (CO) levels in flue gas.
  • Page 99 FIGURE A.1a: GAS VALVE DETAIL (80MBH THRU 120MBH) FIGURE A.1b: GAS VALVE DETAIL (150MBH, 180MBH) Table A.2: Starting Number of Throttle Turns for Conversion to LP Gas Model # Counter-clockwise Turns (From Fully Closed) K2-080 3-3/4 K2-100 K2-120 K2-150 2-3/4...
  • Page 100 Appendix A - (continued) 6) Perform a combustion test, sampling flue products from the tap in the front of the vent adaptor. 7) While the burner is at high fire adjust the throttle as needed to obtain the CO (or O ) settings shown in the Table A.3: •...

  • Page 101: Appendix B: Instructions For High Altitude Installations Above 2000 Ft

    If installing K2-080 or K2-180, do not attempt to convert K2-080 for use with LP at altitudes above 2000 ft. Also, do not attempt to convert K2-180 for use with LP gas at altitudes above 7800 ft. Attempts to do so may result in unreliable operation, property damage, personal injury or loss of life due to carbon monoxide (CO) poisoning.
  • Page 102 Table and LP B1 of this Supplement, adjust throttle screw 1. Confirm K2 boiler size, type and installed altitude such that the CO falls in this range while boiler prior to startup. Install boiler in accordance with the is locked manually in high fire.
  • Page 103 Appendix B - (continued) Table B1: K2 Altitude Adjustments (Above 2000 ft. only) Measured CO Approximate De-rate per 1000 Ft. Model Fuel Derate/1000 ft. Derate/1000 ft. Derate/1000 ft. 2000-4500 ft. 4501-7800 ft. 7801-10,200 ft. 2000-4500 ft. 4501-7800 ft. 7801-10,200 ft.

  • Page 104: Commonwealth Of Massachusetts

    Appendix C: Special Requirements For Side-Wall Vented Appliances In The Commonwealth of Massachusetts IMPORTANT The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4.00 and 5.00 for installation of side-wall vented gas appliances as follows: (a) For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) ft.
  • Page 105 Appendix C - (continued) 1. Detailed instructions for the installation of the venting system design or the venting system components; and 2. A complete parts list for the venting system design or venting system. (d) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases, but identifies “special venting systems”, the following requirements shall be satisfied by the manufacturer:...
  • Page 106 105294-05 - 5/15...
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  • Page 108 U.S. Boiler Company, Inc. P.O. Box 3020 Lancaster, PA 17604 1-888-432-8887 www.usboiler.net 105294-05 - 5/15...

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