Energy Star K2 Operating Instructions Manual

Text of Energy Star K2 User Guide:

• Energy Star K2, 24 105337-02 - 9/14 Figure 4: 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 71.1°C) Radiant Baseboard 140°F to 160°F (60°C to 71.1°C) Radiators Outdoor Air Temperature -20 105-15 -10 -5 0 110 454020 25 30 35 55 60 65 70 15 50 145 115 150 120 140 135 130 12

• Energy Star K2, 1 105337-02 - 9/14 Price - $5.00 WARNING: Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury, or loss of life. For assistance or additional information, consult a qualied installer, service agency or the gas supplier. This boiler requires a special venting system. Read these instructions carefully before installing. 9700609 As an ENERGY STAR ® Partner, U.S. Boiler Company has determined that the K2™ Series meets the ENERGY STAR ® guidelines for energy efciency established by the United States Environmental Protection Agency (EPA). OPERATING INSTRUCTIONS FOR K2™ CONDENSING HIGH EFFICIENCY DIRECT

• 11 105337-02 - 9/14 I. Operation F. Viewing Boiler Status (continued) F. Viewing Boiler Status 1. Status Screens Boiler Status screens are the primary boiler monitoring screens. The user may simply “walk” though boiler operation by repeatedly selecting the right or left “arrow” symbol. These screens are accessed by selected the “Status” button from the “Home” screen

• 20 105337-02 - 9/14 “Press” Contractor Setup button to access the following parameters: I. Operation G. Changing Adjustable Parameters (continued) Factory Setting Range / Choices Parameter and Description Contractor Name User dened Contractor Name Address Line 1 User dened Contractor Address Line 1 Address Line 2 User dened Contractor Address Line

• Energy Star K2, 2 105337-02 - 9/14 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. All wiring on boilers installed in Canada sh

• Energy Star K2, 17 105337-02 - 9/14 “Press” Pump Setup button to access the following parameters: Factory Setting Range / Choices Parameter and Description Central Heat, Optional Priority Never, Any Demand, Central Heat, No Priority, Central Heat, Optional Priority System Pump run pump for: Activates the system pump output according to selected function. Never: Pump is disabled and not shown on status screen. Any Demand: Pump Runs during any call for heat. Central Heat, No Priority: Pump Runs during central heat and frost protect

• Energy Star K2, 18 105337-02 - 9/14 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. Domestic hot water priority is optional. It is permissible for the domestic and system pumps to run at the same time. The boiler pump must run for every call for heat. Multiple Boilers with B

• Energy Star K2, 30 105337-02 - 9/14 II. Troubleshooting (contined) 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 Sage2.1 Control. Hard Lockout Codes Displayed Lockout Number Condition Possible Cause 4 Supply high limit Sage2.1 supply sensor detected temperatures

• Energy Star K2, 22 105337-02 - 9/14 “Press” Domestic Hot Water button to access the following parameters: Factory Setting Range / Choices Parameter and Description 170°F (76.7°C) 60°F to 190°F (16°C to 87.8°C) Domestic Hot Water Setpoint The Domestic Hot Water (DHW) Setpoint parameter is used to create a minimum boiler water temperature setpoint that is used when DHW heat demand is “on”. When the DHW heat demand is not “on” (the contact is open or not wired) this setpoint is ignored. 160°F (71.1°C) 60°F to 190°F (16°C to 87.8°C) Domestic Hot Water Thermostat “Sleep” or “Away” Setback Setpoint Thermostat setback setpoint is used when the EnviraCOM thermostat is i

• Energy Star K2, 9 105337-02 - 9/14 X. Operation E. Boiler Sequence Of Operation (continued) E. Multiple Boiler Control Sequencer 1. Normal Operation Table 3: Boiler Sequence of Operation Status Screen Display Description Priority: Standby Status: Standby (burner Off, circulator(s) Off) Boiler is not ring and there is no call for heat, priority equals standby. The boiler is ready to respond to a call for heat. Priority: Central Heat Status: Standby (burner Off, circulator(s) On) Boiler is not ring. There is a Central Heat call for heat and the Supply temperature is gr

• Energy Star K2, 29 105337-02 - 9/14 II. Troubleshooting (contined) Lockout Number Condition Possible Cause 13 Flame rod shorted to ground • Flame rod shorted to ground • Condensate Trap plugged. • Shorted or mis-wired ame rode wiring. • Defective ame rod. • Plugged drain line in trap. 14 DT inlet/outlet high Temperature rise between supply and return is too high. • Inadequate boiler water ow. Verify that circulator is operating and that circulator and piping are sized per K2 Installation Instructions Manual, Water Piping and Trim Section. 15 Return temp

• Energy Star K2, 16 105337-02 - 9/14 Control Repair Part P/N 105439-01 Altitude 0 - 2000 Ft. Boiler Type K2-80-02 K2-100-02 K2-120-02 K2-150-02 K2-180-02 Maximum Modulation Rate (RPM) 5100 5500 5100 5400 6000 Minimum Modulation Rate (RPM) 1600 1650 1600 2000 1800 Absolute Maximum Modulation Rate (RPM) 5400 6900 5700 6300 6700 Minimum Light-off Rate (RPM) 3500 3500 3500 3500 3500 Maximum Light-off Rate (RPM) 4000 4000 4000 4000 4000 Table 4: Parameters Changed Using the Boiler Type Parameter Selections: NOTE: Maximum Modulation Rates are designed for 100% nameplate rate at 0°F (-18°C) combustion air. Contact factory before attempting to increase the Maximum Modulation Rate. 2. Adjust

• Energy Star K2, 21 105337-02 - 9/14 I. Operation G. Changing Adjustable Parameters (continued) “Press” Central Heat button to access the following parameters: Factory Setting Range / Choices Parameter and Description 180°F (82.2°C) 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. 170°F (76.7°C) 60°F to 190°F (16°C to 87.8°C) Central Heat Thermostat “Sleep” or “Away” Setback Setpoint Thermostat setback setpoint is used when the EnviraCOM thermostat is in “leave” or “sleep” modes

• Energy Star K2, 7 105337-02 - 9/14 I. Operation C. Boiler Protection Features (continued) Table 2: Frost Protection 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 18

• Energy Star K2, 27 105337-02 - 9/14 II. Troubleshooting (contined) C. Help Screen Faults Indication Condition Possible Cause Sequencer Setup Flashing Sequencer Setup Fault This alarm is active if the slave boiler has lost communication with the Sequence Master. Check the following: - RJ 45 peer-to-peer network disconnected - Sequencer Master was Enabled and then Disabled - Master’s Boiler has been powered down. - To clear fault restore communication or cycle power Boiler Size Setup Flashing Boiler Size Fault WARNING! Boiler size setting may not match actual boiler size. The Boiler size setting determines mi

• Energy Star K2, 8 105337-02 - 9/14 I. Operation D. Multiple Boiler Control Sequencer (continued) 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-To- Boiler Communication” RJ45 connection. 2. Sequenc

• Energy Star K2, 23 105337-02 - 9/14 I. Operation G. Changing Adjustable Parameters (continued) “Press” Outdoor Reset button to access the following parameters: Factory Setting Range / Choices Parameter and Description Enabled Enable Disable Outdoor Reset Enable If an outdoor sensor is installed and Outdoor Reset is Enabled, the boiler will automatically adjust the heating zone set point temperature based on the outdoor reset curve in Figure 2. The maximum set point is dened by the Central Heat Setpoint [factory set to 180°F (82.2°C)] when the outdoor tem

• Energy Star K2, 5 105337-02 - 9/14 I. Operation (A. Overview) A. Overview 1. Sage 2.1 Controller The Sage 2.1 Controller (Control) contains features and capabilities which help improve heating system operation, and efciency. By including unique capabilities, the Control can do more, with less eld wiring, and fewer aftermarket controls and components – improving the operation of both new and replacement boiler installations. 2. Advanced Touch Screen Display 180 F Boiler 1 Energy Save On Max Efficiency On Standby i Status Help Ad

• Energy Star K2, 12 105337-02 - 9/14 Data Logging Real time graphic trends allow users to observe process changes over time providing valuable diagnostic information. For example, ame current performance over start up periods and varying loads can be an indication of gas supply issues. Additionally, supply and return temperature dual pen trends brings a focused look at heat exchanger and pump performance. For example, studying a differential temperature trend may indicate pump speed settings need to be changed. Cycles and Hours Boiler cycles and hours are used to monitor the boilers overall compatibility to the heating load. Excessive cycling compared

• Energy Star K2, 10 105337-02 - 9/14 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” after 4 minutes. The “Home Screen” displays boiler temperature, boiler status and Efciency Information. “Energy Save On” indication appears when the outdoor reset or setback features have lowered t

• Energy Star K2, 14 105337-02 - 9/14 I. Operation G. Changing Adjustable Parameters (continued) 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 provid

• 6 105337-02 - 9/14 I. Operation B. Supply Water Temperature Regulation (contineud) 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, wh

• Energy Star K2, 25 105337-02 - 9/14 I. Operation G. Changing Adjustable Parameters (continued) Factory Setting Range / Choices Parameter and Description Local Local, 4-20mA Central Heat Modulation Source This parameter enables the 4-20mA input to control ring rate and the thermostat input to control boiler on/off demand directly without using the internal setpoint. The 4-20mA selection is used to enable a remote multiple boiler controller to control the Sage2.1 Control: Local: 4-20mA Input on Terminal 9 & 10 is ignored. 4-20mA 4-20mA Input on Terminal 9 & 10 is used to contro

• 3 105337-02 - 9/14 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

• Energy Star K2, 28 105337-02 - 9/14 Soft Lockout Codes Displayed 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. Lockout Number Condition Possible Cause 1 Anti Short Cycle Minimum time between starts has not been reached. Norma

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