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

Condensing high efficiency direct vent gas - fired hot water boiler
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See also: Instruction and Installation Manual

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
105337-03 - 5/15

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Summary of Contents for U.S. Boiler Company K2

  • 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 105337-03 - 5/15...

  • Page 5: Operation

    i. Operation A. Overview 5. Built-in Safety Control 1. Sage2.2 Controller The Control includes safety controls designed to ensure safe and reliable operation. In addition to flame safety controls The Sage2.2 Controller (Control) contains features and the Control includes supply water temperature, differential capabilities which help improve heating system operation, water temperature, and stack temperature safety limits and efficiency.
  • Page 6 i. Operation B. Supply Water Temperature Regulation Heat call for heat the setpoint is either the user entered Auxiliary Heat Setpoint or is automatically adjusted as 1. Priority Demand a thermostat’s “sleep” or, Away Modes or, Outdoor Air The Control accepts a call for heat (demand) from Reset multiple places and responds according to it’s “Priority”.

  • Page 7: Boiler Protection Features

    i. Operation 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 The control is equipped with internal operating any of these limits open the boiler will shut down and control and high limit features.

  • Page 8: Multiple Boiler Control Sequencer

    i. Operation 6. Multiple Demands D. Multiple Boiler Control Sequencer The Sequence Master responds to Central Heat, Auxiliary 1. “Plug & Play” Multiple Boiler Control Sequencer Heat, DHW and frost protection demands similar to the When multiple boilers are installed, the Control’s stand alone boiler.

  • Page 9: Normal Operation

    X. Operation E. Boiler Sequence of Operation 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 “Home Screen” after 4 minutes. The “Home Screen” provides boiler temperature, firing rate in BTU/hr, boiler status, efficiency information and page links. Boiler number and Tankless indication shows “Tankless” when configured for K2 Combi Kit rate Menu Buttons Firing rate is displayed as kbtu/hr input.
  • Page 11 i. 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 12: Bargraph Screen

    i. Operation E. Boiler Sequence Of Operation (continued) 3. Status Screens (continued) Bargraph Screen Bargraph Screen The bargraph screen presents measured values for easy comparison. Trend Screens Data Logging Real time graphic trends allow users to observe process changes over time providing valuable diagnostic information.
  • Page 13 i. Operation E. Boiler Sequence Of Operation (continued) Circulator Status Screen Pumping is a major part of any hydronic system. This screen provides the status of the boiler’s demand to connected pumps as well as the status of Frost Protection and pump Exercise functions. Head Demand Screen This screen provides the status of the boilers five (5) possible heat demands.

  • Page 14: Multiple Boiler Sequencer Screens

    i. Operation E. Boiler Sequence Of Operation (continued) 5. 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.

  • Page 15: Changing Adjustable Parameters

    i. Operation F. 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 16 i. Operation F. Changing Adjustable Parameters (continued) 2. Adjusting Parameters (continued) The following pages describe the Control’s adjustable parameters. Parameters are presented in the order they appear on the Control’s Display, from top to bottom and, left to right. From the “Home” screen select the Adjust button to access the adjustment mode screens show below (if required, refer to the previous page to review how to enter Adjustment mode): System “Press”...
  • Page 17 i. 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 18 Operation F. Changing Adjustable Parameters (continued) Table 4: Parameters Changed Using the Boiler Type Parameter Selections: Control repair Part Kit Part Number 106194-01 altitude 0 - 2000 Ft. Parameter K2-80-02 K2-100-02 K2-120-02 K2-150-02 K2-180-02 Maximum Heat Rate (RPM) 5100 5500...
  • Page 19 i. 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 20 i. Operation F. 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 21 i. Operation F. 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...

  • Page 22: Wiring Locations

    i. 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 23 i. Operation F. 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.

  • Page 24: Response Speed

    i. Operation F. 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 25 i. 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 26 Domestic Hot Water Heater Type Tank Selected when boiler is piped to an indirect water heater. Tankless Selected when a K2 Combi Kit is attached to the boiler. Tank Tank, Tankless When selected special parameters are entered to allow the required Combi rate of response.
  • Page 27 i. 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 28 X. 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 29 i. Operation F. Changing Adjustable Parameters (continued) Figure 8: 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 30 i. Operation F. Changing Adjustable Parameters (continued) Sequence “Press” button to access the following parameters: Master 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. Warning! enable Disable ONLY one Sequence Master.
  • Page 31 i. Operation F. Changing Adjustable Parameters (continued) “Press” button to access the following parameters: NOTE Zone Control Description Setup shown for 2 panels, typical for up to 4. Use Up and DOWN Arrows for More Exit Screen without Saving Clear Entire Field Backspace Save Field and Exit Factory Setting...
  • Page 32 i. 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 33: 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 34 II. 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 35 II. 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 is steady; the “open” contact icon is blinking.

  • Page 36: 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 37 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 38: Alarm Output Contact

    • 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 39 105337-03 - 5/15...
  • Page 40 U.S. Boiler Company, Inc. P.O. Box 3020 Lancaster, PA 17604 1-888-432-8887 www.usboiler.net 105337-03 - 5/15...

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