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.
IMPORTANT INFORMATION - READ CAREFULLY NOTE: The equipment shall be installed in accordance with those installation regulations enforced in the area where the installation is to be made. These regulations shall be carefully followed in all cases. Authorities having jurisdiction shall be consulted before installations are made. All wiring on boilers installed in the USA shall be made in accordance with the National Electrical Code and/or local regulations.
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. Installation and service must be performed only by an experienced, skilled, and knowledgeable installer or service agency.
Table of Contents I. Operation 5 II.
I. Operation A. Overview 1. Sage2.2 Controller The Sage2.2 Controller (Control) contains features and capabilities which help improve heating system operation, and efficiency. By including unique capabilities, the Control can do more, with less field wiring, and fewer aftermarket controls and components – improving the operation of both new and replacement boiler installations. 2. Advanced Touch Screen Display 5.
I. Operation B. Supply Water Temperature Regulation 1. Priority Demand The Control accepts a call for heat (demand) from multiple places and responds according to it’s “Priority”. When more than 1 demand is present the higher priority demand is used to determine active boiler settings. For example, when Domestic Hot Water (DHW) has priority the setpoint, “Diff Above”, “Diff Below” and pump settings are taken from DHW selections. Active “Priority” is displayed on the “Boiler Status” screen.
I. Operation C. Boiler Protection Features 1. Supply Water Temperature High Limit The control is equipped with internal operating control and high limit features. The control monitors a dual element temperature sensor that is mounted in the supply water manifold and provides UL353 and UL1998 internal safety algorithms. If supply water temperature increases above the active setpoint plus diff above, default 190°F (87.7°C) the boiler is cycled off. If the temperature exceeds 210°F (98.
I. Operation D. Multiple Boiler Control Sequencer 1. “Plug & Play” Multiple Boiler Control Sequencer When multiple boilers are installed, the Control’s Sequencer may be used to coordinate and optimize the operation of up to eight (8) boilers. Boilers are connected into a “network” by simply “plugging in” standard ethernet cables into each boiler’s “Boiler-ToBoiler Communication” RJ45 connection. 2. Sequencer Master A single Control is parameter selected to be the Sequencer Master.
X. Operation E. Boiler Sequence of Operation 1. Normal Operation Table 3: Boiler Sequence of Operation Status Screen Display Priority: Standby Status: Standby Description (burner Off, circulator(s) Off) Boiler is not firing and there is no call for heat, priority equals standby. The boiler is ready to respond to a call for heat. (burner Off, circulator(s) On) Priority: Central Heat Boiler is not firing.
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. 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” after 4 minutes.
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” button from the “Home” screen. NOTE Only visible if Zone Panel is connected. Zone Panel 1 and 2 shown typical for 1 through 4. Figure 3: Status Screen Overview Supply: Measured supply water temperature.
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. For example, flame current performance over start up periods and varying loads can be an indication of gas supply issues.
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. When demand is off the Control has not detected the call-for-heat.
I. Operation E. Boiler Sequence Of Operation (continued) 5. Multiple Boiler Sequencer Screens When the Sequence Master is enabled the following screens are available: The Sequencer Status screen is selected by “pressing” “Status” button from the “Home” screen when Sequence Master is enabled. Header: measured header water temperature. This is the temperature being used to start, stop and fire boiler when there is a call-for-heat.
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” button on the “Home” screen. Press the “Adjust” button on the Adjust Mode screen or Press “Service Contact” for service provider contact information.
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.
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. Incorrect boiler type can cause hazardous burner conditions and improper operation that may result in PROPERTY LOSS, PHYSICAL INJURY OR DEATH.
I. 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 Parameter 0 - 2000 Ft.
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" the Control first uses the expected heat rate value to set a maximum heat rate.
I. Operation F. Changing Adjustable Parameters (continued) “Press” Pump Setup button to access the following parameters: Factory Setting Range / Choices Central Heat, Optional Priority Never, Any Demand, Central Heat, No Priority, Central Heat, Optional Priority Any Demand Primary Loop Pipe IWH Any Demand, Header Sensor Demand Never, Primary Loop Piped IWH, Parameter and Description System Pump run pump for: Activates the system pump output according to selected function.
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 system pump to run or not run when there is a domestic hot water call for heat.
I. Operation F.
I. Operation F. Changing Adjustable Parameters (continued) “Press” Contractor Setup button to access the following parameters: i Contractor Name For Service Contact: Bill Smith 12 Victory Lane Plainview, New York 516 123-4567 Press box to input contractor information. < > Bill Smith Save Press SAVE button to store revisions.
I. Operation F. Changing Adjustable Parameters (continued) “Press” Central Heat button to access the following parameters: Factory Range / Choices Setting Parameter and Description 60°F to 190°F (16°C to 87.8°C) Central Heat Setpoint Target temperature for the central heat priority. Value also used by the outdoor air reset function. 60°F to 190°F (16°C to 87.
I. Operation F. Changing Adjustable Parameters (continued) “Press” button to access the following parameters: Factory Setting Range / Choices 180°F (82.2°C) 60°F to 190°F (16°C to 87.8°C) 170°F (76.7°C) Parameter and Description Auxiliary Heat Setpoint Target temperature for the Auxiliary Heat priority. Value also used by the outdoor air reset function.
I. Operation F. Changing Adjustable Parameters (continued) “Press” Factory Setting Domestic Hot Water button to access the following parameters: Range / Choices Parameter and Description Tank Tank, Tankless 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. When selected special parameters are entered to allow the required Combi rate of response.
I. Operation F. Changing Adjustable Parameters (continued) “Press” Factory Setting Enabled button to access the following parameters: Range / Choices Enable Disable Parameter and Description 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. The maximum set point is defined by the Central Heat Setpoint [factory set to 180°F (82.
X. Operation F. Changing Adjustable Parameters (continued) “Press” Factory Setting Enabled button to access the following parameters: Range / Choices Enable Disable Parameter and Description 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. The maximum set point is defined by the Central Heat Setpoint [factory set to 180°F (82.
I. Operation F. Changing Adjustable Parameters (continued) Figure 8: Outdoor Reset Curve Central Heat Setpoint Heating Element Type Central Heat Setpoint Heating Element Type 180°F to 190°F (82.2°C to 87.8°C) Fan Coil 100°F to 140°F (37.8°C to 60°C) In Slab Radiant High Mass Radiant 160°F to 190°F (71.1°C to 87.8°C) Convection Baseboard Fin Tube Convective 130°F to 160°F (54.4°C to 71.1°C) Staple-up Radiant Low Mass Radiant 130°F to 160°F (54.4°C to 71.
I. Operation F. Changing Adjustable Parameters (continued) “Press” Sequence Master button to access the following parameters: Factory Setting Range / Choices Disable Enable, Disable Boiler Piped Boiler Piped, Primary Piped Disabled Enable, Disable 180 Secs 120 - 1200 Secs 195°F (90.6°C) Central Heat Setpoint, 195°F (90.6°C) 70% 50% - 100% 3 1-5 “Press” Sequence Slave Master Enable/Disable The Sequencer Master Enable/Disable is used to “turn on” the Multiple Boiler Controller.
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.
I. Operation F. Changing Adjustable Parameters (continued) “Press” Factory Setting button to access the following parameters: Range / Choices Parameter and Description 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. The 4-20mA selection is used to Local, Local enable a remote multiple boiler controller to control the Sage2.
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 “Priority” show “Standby”. Boiler not responding to a call for heat, “Status” shows “Standby” and “Priority” shows Central Heat or Domestic Hot Water. Boiler is not seeing call for heat.
II. Troubleshooting (continued) C. Help Screen Faults Indication Condition Zone Panel 1 Setup Flashing Zone Panel Failure Zone Panel Setup 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 issue: • Wiring between panel and boiler.
II. Troubleshooting (continued) E. Active Fault Screen Faults Indication Condition Limit String Status i Limit String Status Limits Limit String Fault Flow Switch Air Proving Switch Sensor Status NOTE: Since the limit string items are wired in series, all limits downstream of the “open” limit will also appear on the screen as “open” (blinking) icons regardless of whether or not they are actually open. The Air Proving Switch is wired independent to all other limits.
II. Troubleshooting (continued) F. Troubleshooting problems where a Soft Lockout Code is displayed. When a soft lockout occurs, the boiler will shut down, the display will turn red and the “Help” button will “blink”. Select the “blinking” “Help” button to determine the cause of the soft lockout. The boiler will automatically restart once the condition that caused the lockout is corrected.
II. Troubleshooting (continued) Soft Lockout Codes Displayed (continued) Lockout Number Condition 13 • Flame rod shorted to ground • Flame rod shorted to ground Condensate Trap plugged. 14 Temperature rise between supply and return DT inlet/outlet high is too high. The Control is reading a return sensor 15 temperature higher than the supply sensor Return temp temperature. Condition must be present for higher than supply at least 75 seconds for this error code to appear.
II. Troubleshooting (continued) G. Troubleshooting problems where a Hard Lockout Code is displayed. When a hard lockout occurs, the boiler will shut down, the display will turn red and the “Help” button will “blink”. Select the “blinking” “Help” button to determine the cause of the Hard Lockout. Once the condition that caused the lockout is corrected, the boiler will need to be manually reset using the Reset button on the “Active Fault” display or located on the Sage2.2 Control.
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U.S. Boiler Company, Inc. P.O. Box 3020 Lancaster, PA 17604 1-888-432-8887 www.usboiler.
