aPEX - All Categories On Thermal Solutions Products LLC

aPEX - All Categories On Thermal Solutions Products LLC
INSTALLATION, OPERATING AND
SERVICE INSTRUCTIONS FOR
APEX™
CONDENSING HIGH EFFICIENCY
DIRECT VENT
GAS - FIRED HOT WATER BOILER
Models:
•
•
•
•
•
APX425C
APX525C
APX625C
APX725C
APX825C
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 qualified installer, service agency or the
gas supplier. This boiler requires a special venting system. Read these instructions carefully before installing.
106308-04 - 2/17
Price - $5.00
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 shall be made in accordance with the Canadian Electrical Code and/or local regulations.
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.
The Commonwealth of Massachusetts requires this product to be installed by a Licensed Plumber or Gas Fitter.
The following terms are used throughout this manual to bring attention to the presence of hazards of various risk levels,
or to important information concerning product life.
DANGER
Indicates an imminently hazardous situation
which, if not avoided, will result in death, serious
injury or substantial property damage.
WARNING
Indicates a potentially hazardous situation
which, if not avoided, could result in death,
serious injury or substantial property damage.
CAUTION
Indicates a potentially hazardous situation
which, if not avoided, may result in moderate or
minor injury or property damage.
NOTICE
Indicates special instructions on installation,
operation, or maintenance which are important
but not related to personal injury hazards.
WARNING
Explosion Hazard. DO NOT store or use gasoline or other flammable vapors or liquids in the vicinity of this
or any other appliance.
If you smell gas vapors, DO NOT try to operate any appliance - DO NOT touch any electrical switch or use
any phone in the building. Immediately, call the gas supplier from a remotely located phone. Follow the
gas supplier’s instructions or if the supplier is unavailable, contact the fire department.
2
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. If there is no carbon monoxide detector with an alarm already installed in compliance with the most current edition of
NFPA 720, NFPA 70 and the Massachusetts State Building Code in the residential unit served by the sidewall horizontally
vented gas fueled equipment, a battery operated carbon monoxide detector with an alarm shall be installed in compliance
with the most current edition of NFPA 720, NFPA 70 and the Massachusetts State Building Code.
2. In addition to the above requirements, if there is not one already present, a carbon monoxide detector with an alarm
and a battery back-up shall be installed and located in accordance with the installation requirements supplied with the
detector on the floor level where the gas equipment is installed. The carbon monoxide detector with an alarm shall
comply with 527 CMR, ANSI/UL 2034 Standards or CSA 6.19 and the most current edition of NFPA 720. In the event
that the requirements of this subdivision can not be met at the time of the completion of the installation of the equipment,
the installer shall have a period of thirty (30) days to comply with this requirement; provided, however, that during
said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed in compliance
with the most current edition of NFPA 720, NFPA 70 and the Massachusetts State Building Code. In the event that the
sidewall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the carbon monoxide detector
may be installed on the next adjacent habitable floor level. Such detector may be a battery operated carbon monoxide
detector with an alarm and shall be installed in compliance with the most current edition of NFPA 720, NFPA 70 and the
Massachusetts State Building Code.
3. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height
of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled
heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, “GAS VENT
DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.
4. A final inspection by the state or local gas inspector of the sidewall horizontally vented equipment shall not be performed
until proof is provided that the state or local electrical inspector having jurisdiction has granted a permit for installation of
carbon monoxide detectors and alarms as required above.
B. EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a) 1 through 4:
1. The equipment listed in Chapter 10 entitled “Equipment Not Required To Be Vented” in the most current edition of NFPA
54 as adopted by the Board; and
2. Product Approved sidewall horizontally vented gas fueled equipment installed in a room or structure separate from the
dwelling, building or structure used in whole or in part for residential purposes.
C. When the manufacturer of Product Approved sidewall horizontally vented gas equipment provides a venting system design
or venting system components with the equipment, the instructions for installation of the equipment and the venting system
shall include:
1. A complete parts list for the venting system design or venting system; and
2. Detailed instructions for the installation of the venting system design or the venting system components.
D. When the manufacturer of a Product Approved sidewall horizontally vented gas fueled equipment does not provide the parts
for venting flue gases, but identifies “special venting systems”, the following shall be satisfied:
1. The referenced “special venting system” instructions shall be included with the appliance or equipment installation
instructions; and
2. The “special venting systems” shall be Product Approved by the Board, and the instructions for that system shall include a
parts list and detailed installation instructions.
E. A copy of all installation instructions for all Product Approved sidewall horizontally vented gas fueled equipment, all venting
instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or
equipment at the completion of the installation.
3
TABLE OF CONTENTS
I.
Product Description, Specifications and Dimensional Data......................
5
II.
Unpacking Boiler........................................................................................
9
III.
Pre-Installation and Boiler Mounting.......................................................... 10
IV.
Venting......................................................................................................
15
A. General Guidelines............................................................................... 15
B. CPVC/PVC Venting.............................................................................. 22
C. Polypropylene Venting......................................................................... 27
D. Stainless Steel Venting........................................................................
32
E. Optional Room Air for Combustion....................................................... 34
F. Removing the Existing Boiler...............................................................
35
G. Multiple Boiler Installation Venting....................................................... 36
V.
Condensate Disposal.................................................................................
39
VI.
Water Piping and Trim............................................................................... 41
VII.
Gas Piping ...............................................................................................
53
VIII. Electrical ................................................................................................... 58
IX.
System Start-Up ....................................................................................... 69
X.
Operation...................................................................................................... 77
A. Basic Operation.................................................................................... 77
B.Features............................................................................................... 77
C. Supply (Outlet) Water Temperature Regulation...................................
78
D. Boiler Protection Features.................................................................... 78
E. Touch Screen Display Navigation........................................................
80
F. Quick Setup.......................................................................................... 81
G. Sequence of Operation........................................................................ 83
H. Status Screens..................................................................................... 84
I. Manual Operation and Tuning.............................................................. 86
J. Parameter Adjustment.......................................................................... 86
K. USB Thumb Drive Parameter Transfer................................................ 103
L. Multiple Boiler Control Sequencer....................................................... 105
M. Energy Management System (EMS) Interface.................................... 108
XI.
Service and Maintenance ........................................................................ 115
XII.
Troubleshooting........................................................................................ 121
XIII. Repair Parts ............................................................................................. 136
Appendix A - Instructions for High altitude Installations Above 2000 ft..... 151
Appendix B - Figures................................................................................ 154
Appendix C - Tables.................................................................................. 157
Warranty...........................................................................................Back Page
4
I. Product Description, Specifications and Dimensional Data
Apex Series boilers are condensing high efficiency gas-fired
direct vent hot water boilers designed for use in forced hot
water space or space heating with indirect domestic hot
water heating systems, where supply water temperature
does not exceed 210°F. These boilers have special coil
type stainless steel heat exchangers, constructed, tested and
stamped per Section IV ‘Heating Boilers’ of ASME Boiler
and Pressure Vessel Code, which provide a maximum heat
transfer and simultaneous protection against flue gas product
corrosion. These boilers are not designed for use in gravity
hot water space heating systems or systems containing
significant amount of dissolved oxygen (swimming pool
water heating, direct domestic hot water heating, etc.).
Table 1: Specifications
Specification
Altitude (ft. above sea level)
1
Fuel
Max. Allowable Water Temperature (°F)
Max. Allowable Working Pressure (psi)
Factory Supplied Safety Relief Valve (psi)*
Boiler Water Volume (gal.)
Heat Transfer Area (sq. ft.)
Approx. Shipping Weight (lb.)
APX425C
APX525C
0-10,100
0-10,100 2
Shipped for Natural Gas, Field
Converted for LP Gas
210
210
160
160
50
50
3.4
4.3
41.8
58.1
316
368
* Optional 80 psi and 100 psi safety relief valves are available for all models.
1
2
3
4
Boiler Model
APX625C
APX725C
APX825C
0-10,100
0-10,100 3
0-6,000 4
Shipped for Natural Gas or Shipped for LP Gas
(no Field Conversion)
210
210
210
160
160
160
60
60
60
5.4
5.4
6.2
76.2
76.2
87.0
458
458
500
Follow Instructions for High Altitude Installations above 2000 ft. (see Appendix A)
APX525C LP cannot be installed above 6,000 ft.
APX725C LP cannot be installed above 7,800 ft.
APX825C natural gas cannot be installed above 6,000 ft. APX825C LP can be installed up to 10,100 ft.
Table 2: Dimensions (See Figures 1, 2, and 3)
Dimension
A - Inch
(mm)
B - Inch
(mm)
C - Inch
(mm)
D - Inch
(mm)
E - Inch
(mm)
Gas Inlet G - Inch
Return H - Inch
Supply J - Inch
PP Condensate Drain K - Inch
PVC Combustion Air Connector - Inch
CPVC/PP/SS Vent Connector - Inch
(mm)
Boiler Model
APX425C
APX525C
APX625C
APX725C
APX825C
31-3/16
(792)
5-1/2
(140)
12-3/8
(314)
23
(584)
15-1/8
(384)
46-1/2
(1181)
49-1/2
(1258)
49-1/2
(1258)
53-5/16
(1258)
N/A
N/A
N/A
N/A
21-5/16
23-1/4
23-1/4
(541)
(591)
(591)
34-13/16
38-1/16
38-1/16
(884)
(967)
(967)
28-5/16
30-7/8
30-7/8
(719)
(784)
(784)
3/4 (FPT)
1 (FPT)
1-1/2 FPT
2 MPT
1-1/2 FPT
2 MPT
3/4 PVC Compression Coupling
4
4
(100)
23-7/16
(596)
41-3/16
(1046)
32-9/16
(827)
6
(150)
5
6
1
12 2 "
1
58"
1
52"
4" PVC COMBUSTION
AIR CONNECTOR
4" CPVC/PP/SS
VENT CONNECTOR
9
2 16 "
'H' 1-1/2" FPT
RETURN TAPPING
ACCESS PANEL
'A'
'K'
CONDENSATE DRAIN
ACCESS PANEL
'C'
'B'
5
5 16 "
5
17 16 "
1
32 2 "
1
14"
1
24"
Figure 1: Apex - Model APX425C
'E'
ACCESS PANEL
3/4" FPT
RELIEF/DRAIN
TAPPING
'D'
13
7 16 "
LOW VOLTAGE
KNOCKOUTS
(24 VOLTS)
'J' 1-1/2" FPT
SUPPLY TAPPING
ACCESS PANEL
'G'
GAS VALVE INLET
LINE VOLTAGE
KNOCKOUTS
(120 VOLTS)
ACCESS PANEL
1
43 2 "
I. Product Description, Specifications and Dimensional Data (continued)
7
16 8 "
7
1
15 2 "
1
88"
1
52"
4" PVC COMBUSTION
AIR CONNECTOR
4" CPVC/PP/SS
VENT CONNECTOR
9
2 16 "
ACCESS PANEL
5
8 16 "
ACCESS PANEL
'D'
'E'
'C'
'G'
GAS VALVE INLET
LINE VOLTAGE
KNOCKOUTS
(120 VOLTS)
LOW VOLTAGE
KNOCKOUTS
(24 VOLTS)
Figure 2: Apex - Model APX525C
'A'
ACCESS PANEL
'K'
CONDENSATE DRAIN
'J' 2" MPT SUPPLY
TAPPING
'H' 2" MPT
RETURN TAPPING
ACCESS PANEL
ACCESS PANEL
3
58"
I. Product Description, Specifications and Dimensional Data (continued)
1
35 16 "
3
12 8 "
5
20 16 "
1
14"
1
24"
7
16 8 "
8
9
15 16 "
1
7 16 "
1
88"
4" PVC COMBUSTION
AIR CONNECTOR
6" CPVC/PP/SS
VENT CONNECTOR
9
2 16 "
ACCESS PANEL
'A'
ACCESS PANEL
'D'
'C'
'G'
GAS VALVE INLET
'E'
'J' 2" MPT
SUPPLY TAPPING
LINE VOLTAGE
KNOCKOUTS
(120 VOLTS)
7
68"
LOW VOLTAGE
KNOCKOUTS
(24 VOLTS)
Figure 3: Apex - Models APX625C, APX725C and APX825C
5
8 16 "
ACCESS PANEL
'K'
CONDENSATE DRAIN
'H' 2" MPT
RETURN TAPPING
ACCESS PANEL
ACCESS PANEL
I. Product Description, Specifications and Dimensional Data (continued)
5
10 16 "
5
20 16 "
1
35 16 "
1
14"
1
24"
7
16 8 "
I. Product Description, Specifications and Dimensional Data (continued)
Table 3: Ratings
Apex Series Gas-Fired Boilers
Input (MBH)
Model
Number
Min.
Max.
APX425C
80
399
Gross Output Net Ratings Water 1
(MBH)
(MBH)
375
Thermal
Efficiency (%)
Combustion
Efficiency (%)
94.1
94.5
326
APX525C
100
500
485
422
97.0
96.0
APX625C
125
625
594
517
95.0
96.0
APX725C
145
725
689
599
95.0
95.0
APX825C
160
800
760
661
95.0
94.0
Ratings shown are for installations at sea level and elevations up to 2000 ft. at minimum vent length. For elevations above 2000
ft., see Appendix A Instructions for High Altitude Installations above 2000 ft.
1
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.
II. Unpacking Boiler
NOTICE
Do not drop boiler.
D. Remove boiler from cardboard positioning sleeve
on shipping skid.
E. Move boiler to its permanent location.
A. Move boiler to approximate installed position.
B. Remove all crate fasteners.
C. Lift and remove outside container.
9
III. Pre-Installation and Boiler Mounting
WARNING
Explosion Hazard. Asphyxiation Hazard.
Electrical Shock Hazard. Installation of this
boiler should be undertaken only by trained
and skilled personnel from a qualified service
agency. Follow these instructions exactly.
Improper installation, adjustment, service,
or maintenance can cause property damage,
personal injury or loss of life.
NOTICE
Due to the low water content of the boiler, missizing of the boiler with regard to the heating
system load will result in excessive boiler
cycling and accelerated component failure.
Thermal Solutions DOES NOT warrant failures
caused by mis-sized boiler applications. DO
NOT oversize the boiler to the system. Multiple
boiler installations greatly reduce the likelihood
of boiler oversizing.
1. Access to boiler front is provided through a door or
removable front access panel.
2. Access is provided to the condensate trap located
underneath the heat exchanger.
3. Access is provided to thermal link located at boiler
rear.
D. Protect gas ignition system components
from water (dripping, spraying, rain, etc.) during
boiler operation and service (circulator replacement,
condensate trap, control replacement, etc.).
E. Provide combustion and ventilation air in
accordance with applicable provisions of local building
codes, or: USA - National Fuel Gas Code, ANSI
Z223.1/NFPA 54, Air for Combustion and Ventilation;
Canada - Natural Gas and Propane Installation Code,
CAN/CSA-B149.1, Venting Systems and Air Supply for
Appliances.
Table 4: Corrosive Combustion Air Contaminants
and Sources
Contaminants to avoid:
Spray cans containing chloro/fluorocarbons (CFC’s)
Permanent wave solutions
WARNING
Asphyxiation Hazard.
Apply supplied dielectric grease to gasket
inside vent connector. Failure to apply the
grease could result in flue gas leaks from gasket
rupture during vent pipe installation or gasket
deterioration due to condensate exposure.
A. Installation must conform to the requirements
of the authority having jurisdiction in or, in the absence
of such requirements, to the National Fuel Gas Code,
ANSI Z223.1/NFPA 54, and/or Natural Gas and
Propane Installation Code, CAN/CSA B149.1.
Where required by the authority having jurisdiction, the
installation must conform to the Standard for Controls
and Safety Devices for Automatically Fired Boilers,
ANSI/ASME CSD-1.
B. Boiler is certified for installation on combustible
flooring. Do not install boiler on carpeting.
C. Provide clearance between boiler jacket and
combustible material in accordance with local fire
ordinance. Refer to Figure 4 for minimum listed
clearances from combustible material. Recommended
service clearance is 24 in. (610 mm) from left side,
front, top and rear of the boiler. Recommended front
clearance may be reduced to the combustible material
clearance providing:
10
Chlorinated waxes/cleaners
Chlorine-based swimming pool chemicals
Calcium chloride used for thawing
Sodium chloride used for water softening
Refrigerant leaks
Paint or varnish removers
Hydrochloric acid/muriatic acid
Cements and glues
Antistatic fabric softeners used in clothes dryers
Chlorine-type bleaches, detergents, and cleaning solvents found
in household laundry rooms.
Adhesives used to fasten building products and other similar
products
Excessive dust and dirt
Areas likely to have contaminants:
Dry cleaning/laundry areas and establishments
Swimming pools
Metal fabrication plants
Beauty shops
Refrigeration repair shops
Photo processing plants
Auto body shops
Plastic manufacturing plants
Furniture refinishing areas and establishments
New building construction
Remodeling areas
Garages with workshops
III. Pre-Installation and Boiler Mounting (continued)
b. Boiler must be level to prevent condensate from
backing up inside the boiler.
c. Provide adequate space for condensate piping or
a condensate pump if required.
WARNING
Asphyxiation Hazard. Adequate combustion and
ventilation air must be provided to assure proper
combustion. Install combustion air intake per
Section IV “Venting”.
F. The boiler should be located so as to minimize
the length of the vent system. Locate combustion air
pipe termination away from areas that may contaminate
combustion air, (see Table 4). In particular, avoid
areas near chemical products containing chlorines,
chlorofluorocarbons, paint removers, cleaning solvents
and detergents. Avoid areas containing saw dust, loose
insulation fibers, dry wall dust etc.
NOTICE
Avoid operating this boiler in an environment
where sawdust, loose insulation fibers, dry wall
dust, etc. are present. If boiler is operated under
these conditions, the burner interior and ports
must be cleaned and inspected daily to insure
proper operation.
G.General.
1. Apex boilers are intended for installations in an
area with a floor drain, or in a suitable drain pan to
prevent any leaks or safety relief valve discharge
resulting in property damage.
2. Apex boilers are not intended to support external
piping and venting. All external piping and venting
must be supported independently of the boiler.
3. Apex boilers must be installed level to prevent
condensate from backing up inside the boiler.
Boiler Clearances to Combustible (and NonCombustible) Material:
Models APX425C and APX525C:
These boilers are listed for closet installation with the following minimum clearances – Top = 1 in. (25 mm), Front = 1 in. (25 mm), Left Side = 10 in. (250 mm), Right Side = 2 in. (50 mm), Rear = *6 in. (150 mm)
Models APX625C, APX725C and APX825C:
These boilers are listed for alcove installation with the following minimum clearances – Top = 1 in. (25 mm), Front = Open, Left Side = 10 in. (250 mm), Right Side = 2 in. (50 mm), Rear = *6 in. (150 mm)
* Note:
When boiler is vented vertically, the minimum clearance from the rear of the jacket is increased to 18 in. (460 mm) with a short radius 90° elbow provided in order to provide adequate space at boiler rear for installation of vent and air intake piping and service access.
Boiler Service Clearances – Applicable to all Boiler
Models:
Top = 24 in. (610 mm), Front = 24 in. (610 mm), Left Side = 24 in. (610 mm), Right Side = 24 in. (610 mm), Rear = 24 in. (610 mm)
The above clearances are recommended for service access but may be reduced to the Combustible Material Clearances provided:
4. Boiler Installation:
a. For basement installation provide a solid level
base such as concrete where floor is not level or
where water may be encountered on the floor
around boiler. Floor must be able to support
weight of boiler, water and all additional system
components.
1. The boiler front is accessible through a door.
2. Access is provided to the condensate trap located on
the left side of boiler.
3. Access is provided to thermal link located at the
boiler rear.
Table 5: Vent Pipe Clearances to Combustible Material
Listed Direct
Vent System
Standard
Two-Pipe CPVC/PVC Vent and PVC Combustion Air Intake
Vent Pipe Material
Vent Pipe
Enclosure
Direction
CPVC/PVC
Optional
Rigid Polypropylene (or,
Two-Pipe Rigid Polypropylene Vent (or, Flexible Polypropylene Flexible Polypropylene
Liner for Vertical Venting only) and Rigid Polypropylene or PVC Liner for Vertical Venting
only)
Combustion Air Intake
Optional
Two-Pipe Stainless Steel Vent and Galvanized Steel or PVC
Combustion Air Intake
Stainless Steel
Vertical or
Horizontal
Unenclosed
at all Sides
Vent Pipe
Nominal Diameter
Minimum
Clearance to
Combustible
Material
3 in. (80 mm),
4 in. (100 mm or 110 mm),
6 in.( 150 mm or 160 mm)
1 in. (25 mm)
3 in. (80 mm),
4 in. (100 mm or 110 mm),
6 in.( 150 mm or 160 mm)
1 in. (25 mm)
3 in. (80 mm),
4 in. (100 mm or 110 mm),
6 in.( 150 mm or 160 mm)
1 in. (25 mm)
11
III. Pre-Installation and Boiler Mounting (continued)
Figure 4: Clearances To Combustible and Non-combustible Material
b. Each Apex boiler is factory packaged with
2 stacking boiler attachment brackets (P/N
1. For installations with unusually high space heating
101679-01) and the bracket mounting hardware
and/or domestic hot water heating loads, where
[six (6) self-drilling hex washer head plated #8
employing multiple boilers will offer the benefits of
x ½” long screws, P/N 80860743]. Locate and
greater operational efficiency, floor space savings
remove the brackets and the hardware. The
and boiler redundancy, boilers may be installed
stacking boiler attachment bracket has three
stacked maximum one boiler on top of another.
7/32” diameter holes punched in a triangular
Refer to Table 6 “Apex Boiler Model Stacking
pattern. See Figure 5 “Stacking Boiler
Combinations” for details.
Attachment Bracket Placement”.
Table 6: Apex Boiler Model Stacking
c. Apex boiler left and right side panels have a
Combinations
series of dimples at panel top and bottom. These
Bottom
dimples are positioning dimples for stacking
Top Boiler Model
Boiler Model
boiler attachment bracket mounting screws. Side
APX425C
APX425C
panel bottom positioning dimples are evenly
APX525C
APX425C or APX525C
spaced from boiler front and back, while side
APX625C
APX425C, APX525C or APX625C
panel top positioning dimples follow specific
APX725C
APX425C, APX525C, APX625C or APX725C
pattern to compensate for Apex boiler model
APX425C, APX525C, APX625C, APX725C or
variable depth.
APX825C
APX825C
d. Position the upper boiler on top of the bottom
2. To field assemble individual Apex boilers into a
boiler and align boiler front doors and sides flush
with each other.
stackable configuration, use the steps below:
• Place first stacking boiler attachment
a. Position the bottom boiler first. Refer to Sections
bracket onto the upper boiler left side panel,
II “Unpacking Boiler” and III “Pre-Installation
at the panel lower left corner and align
& Boiler Mounting” of the manual for details.
bracket two upper holes with corresponding
Always position higher input boiler model as
side panel lower dimples.
bottom boiler.
H. Boiler Stacking
12
III. Pre-Installation and Boiler Mounting (continued)
•
The remaining lower bracket hole must align
with a matching bottom boiler left side panel
top positioning dimple.
• Once bracket holes and side panel dimple
alignment is verified, attach the bracket to
top and bottom boiler left side panels with
the mounting screws.
e. Repeat above procedure to install second
stacking boiler attachment bracket and secure the
stacked boiler right side panels together at the
front right corner.
f. Install the third stacking boiler attachment
bracket to secure top and bottom boiler left side
panels at the rear left corner. Align the bracket
holes with corresponding positioning dimples in
the top boiler and bottom boiler left side panels,
then secure bracket with the screws.
g. Repeat above procedure to install the fourth
stacking boiler attachment bracket to secure
stacked boiler right side panels at the rear right
corner.
3. Tilt top boiler display downward as shown in
Figure 5.
a. Remove screws attaching display panel to boiler
left and right side panels (two screws per side).
b. On back side of display panel, disconnect three
electrical connectors display, detach two strain
relief cable screws from top of panel, and loosen
two display mounting screws.
c. Remove display, rotate panel 180° relative to
display, reinstall display, and tighten display
mounting screws. Interchange left and right
display panel end caps.
d. On back side of display panel, attach strain
relief cable screws and reconnect three electrical
connectors.
e. Attach downward-tilted panel to top boiler.
4. When installing stackable boiler combinations
observe the following guidelines:
For sidewall venting individual model vent
terminals must terminate no closer than 12
in. (300 mm) horizontally and 3 ft. (900 mm)
vertically from each other in order to prevent
combustion air contamination. For vertical
through the roof venting, individual vertical
vent terminals, if level with each other, must
be spaced no closer than 12 in. (300 mm)
horizontally. If vertical terminals cannot end in
one plane, they must be spaced no closer than 3
ft. (900 mm) horizontally.
Follow instructions in Section IV “Venting”
of the manual for specifics of individual boiler
vent termination. Follow instructions in Section
V “Condensate Disposal” for each individual
boiler flue gas condensate line construction and
condensate disposal. Terminating individual
boiler condensate lines into common pipe prior
to drain disposal is permissible, providing
common pipe has sufficient flow capacity
to handle combined condensate volume of
stackable combination.
b. Gas Piping - Follow instructions in Section
VII “Gas Piping” of the manual for sizing
and installation of an individual boiler. When
common gas piping is sized, insure it will
have adequate capacity for combined input
(CFH gas flow) of the selected stackable boiler
combination.
c. Water Piping and Trim - Follow instructions
in Section VI “Water Piping and Trim” of the
manual for system piping and boiler secondary
piping selection/sizing based on combined
heating capacity and/or gross output of the
selected stackable boiler combination. Follow
instructions of Section VI “Water Piping
and Trim” for each individual boiler trim
installation.
d. Electrical - Follow instructions in Section VIII
“Electrical” of the manual to wire individual
boilers.
a. Venting - Top and bottom boilers must have their
individual vent piping and vent terminals.
WARNING
Asphyxiation Hazard. No common manifold
venting is permitted. Each boiler must have its
own individual vent and combustion air pipes
and terminals.
13
14
Figure 5: Boiler Stacking with Tilted Display Panel
III. Pre-Installation and Boiler Mounting G. General (continued)
IV. 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 use a barometric damper, draft hood or vent damper with this boiler.
Do not locate vent termination under a deck.
Do not locate vent termination where exposed to prevailing winds.
Do not locate combustion air termination where chlorines, chlorofluorocarbons (CFC’s), petroleum
distillates, detergents, volatile vapors or other chemicals are present. Severe boiler corrosion and
failure will result.
Use specified vent and combustion air pipe diameters.
Do not interchange vent systems or materials unless otherwise specified.
Do not apply thermal insulation to vent pipe or fittings.
Moisture and ice may form on surface around vent termination. To prevent deterioration, surface must
be in good repair (sealed, painted, etc.).
Do not allow low spots in the vent where condensate may pool.
The CPVC vent materials supplied with this boiler do not comply with Natural Gas and Propane
Installation Code, CAN/CSA B149.1.S1-07 and are not approved for use in Canadian jurisdictions that
require vent systems be listed to ULC S636-2008. In these jurisdictions, vent this boiler using either
stainless steel Special Gas vent or a listed ULC S636 Class IIB venting system.
A. General Guidelines
1. Listed Vent/Combustion Air Systems
a. Install vent system in accordance with National
Fuel Gas Code, ANSI Z223.1/NFPA 54 or
Natural Gas and Propane Installation Code,
CAN/CSA B149.1 Installation Code for Canada,
or, applicable provisions of local building codes.
Contact local building or fire officials about
restrictions and installation inspection in your
area.
b. The Apex may be installed as a direct vent/
sealed combustion boiler or with optional room
air for combustion. Direct vent is recommended
for residential applications. For direct vent,
pipe combustion air from the outdoors directly
to the boiler cabinet. Room air is optional for
commercial applications. For room air, provide
combustion and ventilation air per the National
Fuel Gas Code, ANSI Z223.1, or, in Canada,
Installation Code for Gas Burning Appliances
and Equipment, CGA Standard B149.
c. The following combustion air/vent system
options are listed for use with the Apex boilers
(refer to Table 7):
i. Two-Pipe CPVC/PVC Vent/Combustion
Air System - Separate CPVC/PVC pipe
serves to expel products of combustion and
separate PVC pipe delivers fresh outdoor
combustion air. Refer to Part B for specific
details.
ii. Two-Pipe Polypropylene Vent/
Combustion Air System - Separate rigid or
flexible polypropylene pipe serves to expel
products of combustion and separate rigid
polypropylene or PVC pipe delivers fresh
outdoor combustion air. Refer to Part C for
specific details.
iii. Two-Pipe Stainless Steel Vent/Combustion
Air System - Separate stainless steel pipe
serves to expel products of combustion
and separate PVC or galvanized steel pipe
delivers fresh outdoor combustion air. Refer
to Part D for specific details.
iv. Room Air for Combustion – CPVC/
PVC, polypropylene, or stainless steel pipe
serves to expel products of combustion and
combustion air is supplied from the boiler
room. Refer to Part E for specific details.
2. Vent/Combustion Air Piping
a. Do not exceed maximum vent/combustion air
lengths listed in Table 8. Vent/combustion
air length restrictions are based on equivalent
length of vent/combustion air pipe (total
length of straight pipe plus equivalent length
of fittings). Table 9 lists equivalent lengths for
fittings. Do not include vent/combustion air
terminals in equivalent feet calculations. Use
vent/combustion air equivalent length worksheet
provided in Table 10.
15
IV. Venting A. General Guidelines (continued)
Table 7: Vent/Combustion Air Intake System Options
Vent & Intake
Materials
Penetration
Through
Structure
Termination
Intake
Horizontal Sidewall
90° Elbow w/ Screen
Vent
Horizontal Sidewall
Coupling w/ Screen
Option
1
2
Standard CPVC/PVC Two-Pipe,
CPVC/PVC
Vent and PVC Air Intake
3
Intake
Horizontal Sidewall
Vent
Horizontal Sidewall
Intake
Horizontal Sidewall
Ipex Low Profile
90° Elbow w/ Screen
Vent
Vertical Roof
Coupling w/ Screen
Intake
Vertical Roof
(2) 90° Elbows w/ Screen
Vent
Vertical Roof
Coupling w/ Screen
4
5
6
Intake
Vent
N/A - Room Air
Horizontal Sidewall
Intake
Vent
N/A - Room Air
Vertical Roof
Coupling w/ Screen
Intake
Horizontal Sidewall
UV Resistant 90° Elbow
w/Screen
Vent
Horizontal Sidewall
UV Resistant Straight Pipe
w/Screen
Intake
Horizontal Sidewall
Vent
Horizontal Sidewall
Intake
Horizontal Sidewall
7
8
Optional Polypropylene
Two-pipe, Rigid PP
Vent or Flexible PP
Vent (Vertical Only) and Rigid PP
or PVC Air Intake
9
UV Resistant Straight Pipe
w/Screen
Intake
Vertical Roof
(2) UV Resistant 90° Elbows
w/Screen
Vent
Vertical Roof
UV Resistant Straight Pipe
w/Screen
Vent
14
Optional Stainless Steel
Two-pipe, SS Vent and
Galvanized Steel or PVC
Air Intake
15
16
Horizontal Sidewall
17
16
UV Resistant 90° Elbow
w/Screen
UV Resistant Straight Pipe
w/Screen
Vertical Roof
Intake
Horizontal Sidewall
90° Elbow w/Screen
Vent
Horizontal Sidewall
Straight Termination
w/Screen
Intake
Horizontal Sidewall
90° Elbow w/Screen
Vent
Vertical Roof
Straight Termination
w/Screen
Intake
Vertical Roof
(2) 90° Elbows w/Screen
Vent
Vertical Roof
Straight Termination
w/Screen
Intake
N/A - Room Air
Horizontal Sidewall
Intake
Vent
7, 8
11, 12
9
13
7, 8, 10
not provided
10
14
7, 8
not provided
10
not provided
7, 8
17, 18
9
13, 17, 18
7, 8, 10
17, 18
10
17, 18
7, 8
17, 18
Reference
Section
A, B
A, B, E
A,C
A,C, E
N/A - Room Air
Vent
Vent
Component
Table
N/A - Room Air
Intake
13
UV Resistant 90° Elbow
w/Screen
Vertical Roof
Intake
12
Ipex Low Profile
Vent
10
11
90° Elbow or Tee w/ Screen
Figures
90° Elbow or Tee w/Screen
N/A - Room Air
Vertical Roof
90° Elbow or Tee w/Screen
10
17, 18
7, 8
19, 20, 21
7, 8, 10
19, 20, 21
10
19, 20, 21
7, 8
19, 20, 21
10
19, 20, 21
A, D
A, D, E
IV. Venting A. General Guidelines (continued)
Table 8: Vent and Combustion Air Pipe Sizes and Equivalent Lengths
(Applies to All Listed Vent/Combustion Air System Options)
Boiler
Model
Option
Standard
Diameter
APX425C
Reduced
Diameter
Standard
Diameter
Reduced
Diameter
Standard
Diameter
Reduced
Diameter
Standard
Diameter
Reduced
Diameter
Standard
Diameter
Reduced
Diameter
APX525C
APX625C
APX725C
APX825C
Combustion Air Length
Vent Length
Pipe Dia., in.
(mm)
Min., ft.
(m)
Max., ft.
(m)
Pipe Dia., in.
(mm)
Min., ft.
(m)
Max., ft.
(m)
Approx. Derate at
Max. Length
(%)
4 (100 or 110)
0
100 (30.5)
4 (100 or 110)
2.5 (760)
100 (30.5)
5
3 (80)
0
50 (15.2)
3 (80)
2.5 (760 )
50 (15.2 )
5
4 (100 or 110)
0
100 (30.5)
4 (100 or 110)
2.5 (760)
100 (30.5)
11
3 (80)
0
50 (15.2)
3 (80)
2.5 (760)
50 (15.2 )
12
4 (100 or 110)
0
100 (30.5)
6 (150 or 160)
2.5 (760)
200 (30.5)
7
4 (100 or 110)
0
50 (15.2)
4 (100 or 110)
2.5 (760)
50 (15.2 )
10
4 (100 or 110)
0
100 (30.5)
6 (150 or 160)
2.5 (760)
200 (30.5)
11
4 (100 or 110)
0
50 (15.2)
4 (100 or 110)
2.5 (760)
50 (15.2 )
15
4 (100 or 110)
0
100 (30.5)
6 (150 or 160)
2.5 (760)
200 (30.5)
14
4 (100 or 110)
0
50 (15.2)
4 (100 or 110)
2.5 (760)
50 (15.2 )
15
Table 9: Vent System and Combustion Air System Component Equivalent Length
(Applies to All Listed Vent/Combustion Air System Options)
Component
Equivalent Length
Nominal Diameter
3 in. (80 mm)
4 in. (100 or 110 mm)
6 in. (150 or 160 mm)
90° Elbow, Short Radius
10 ft. (3.0 m)
13 ft. (4.0 m)
22 ft. (6.7 m)
90° Elbow, Long Sweep/Sanitary
4.0 ft. (1.2 m)
9 ft. (2.7 m)
17 ft. (5.2 m)
45° Elbow
3.0 ft. (0.9 m)
4.5 ft. (1.4 m)
7.5 ft. (2.3 m)
Table 10: Vent and Combustion Air Equivalent Length Calculation Worksheet
Combustion Air
Component
Equivalent
Length Per
Piece
x
Quantity
=
Vent
Subtotal
Equivalent Length
Equivalent
Length Per
Piece
x
Quantity
=
Subtotal Equivalent
Length
Straight Pipe
x
=
A
E
90° Elbow,
Short Radius
x
=
B
F
90° Elbow,
Long Sweep/
Sanitary
x
=
C
G
45° Elbow
x
=
D
H
=
A+B+C+D
Combustion Air Total
Equivalent Length
Vent Total
Equivalent Length
=
E+F+G+H
Notes:
1. Total equivalent length cannot exceed maximum equivalent length shown in Table 8.
2. Use elbow equivalent lengths provided in Table 9.
3. Combustion air and vent terminations do not count towards total equivalent length.
4. Pressure drop for flexible polypropylene liner is 20% greater than for rigid pipe. Multiply measured flexible polypropylene liner
length by 1.2 to obtain equivalent length.
Example
Measured length = 35 ft.
Equivalent length =35 ft. x 1.2 = 42 ft.
5. Maximum equivalent length of flexible polypropylene liner is 48 ft. (14.6 m).
17
18
Figure 6: 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)
IV. Venting A. General Guidelines (continued)
IV. Venting A. General Guidelines (continued)
b. Maintain minimum clearance to combustible
materials. See Table 5 for details.
c. Enclose vent passing through occupied or
unoccupied spaces above boiler with material
having a fire resistance rating at least equal to the
rating of adjoining floor or ceiling.
Note: For one or two family dwellings, fire
resistance rating requirement may not need to be
met, but is recommended.
d. Slope horizontal vent pipe minimum 1/4 in/ft
(21 mm/m) downward towards the boiler.
Les chaudières de catégories I, II et IV doivent
présenter des tronçons horizontaux dont la pente
montante est d’au moins 1/4 po par pied (21
mm/m) entre la chaudière et l’évent.
e. If possible, slope horizontal combustion air
pipe minimum 1/4 in/ft (21 mm/m) downward
towards terminal. If not, slope towards boiler.
f. Use noncombustible ¾ in. pipe strap to support
horizontal runs and maintain vent location and
slope while preventing sags in pipe. Do not
restrict thermal expansion or movement of vent
system. Maximum support spacing 4 ft. (1.2 m).
Avoid low spots where condensate may pool.
Do not penetrate any part of the vent system with
fasteners.
Les instructions d´installation du système
d´évacuation doivent préciser que les sections
horizontales doivent être supportées pour
prévenir le fléchissement. Les méthodes et les
intervalles de support doivent être spécifiés.
Les instructions divent aussi indiquer les
renseignements suivants:
les chaudières de catégories II et IV doivent être
installées de façon à empêcher l´accumulation de
condensat: et
si nécessaire, les chaudières de catégories II et IV
doivent être pourvues de dispositifs d´évacuation
du condensat.
g. For multiple boiler installations with vertical
roof terminals, separate vent pipes from multiple
boilers may be piped through a common conduit
or chase so that one roof penetration may be
made.
3. Vent/Combustion Air Terminals
Install venting system components on exterior
of building only as specifically required by these
instructions (refer to Figure 6).
a. Use only listed vent/combustion air terminals.
i. Horizontal Sidewall Venting: Use coupling
for vent and 90° elbow pointed down for
combustion air as shown in Figure 7 or
Figure 8. If using room air for combustion,
use 90° elbow or tee for vent. Alternate low
profile termination is shown in Figure 9.
Figure 7: Direct Vent - Sidewall Standard Terminations
19
IV. Venting A. General Guidelines (continued)
Figure 8: Direct Vent - Sidewall Snorkel Terminations
Figure 9: Direct Vent - Sidewall Low Profile Termination
ii. Vertical Roof Venting: Use coupling on vent
and two 90° elbows turned downwards for
combustion air as shown in Figure 10 and
Figure 11.
b. Maintain correct clearance and orientation
between vent and combustion air terminals.
i. Space centerlines of vent and combustion air
terminals minimum 12 in. (300 mm) apart.
36 in. (915 mm) spacing is recommended.
ii. If possible, locate vent and combustion
air terminals on the same wall to prevent
nuisance shutdowns. If not, boiler may
be installed with roof vent terminal and
sidewall combustion air terminal.
20
iii. When installed on the same wall, locate
vent terminal at same height or higher than
combustion air terminal.
c. Locate bottom of vent and combustion air
terminals at least 12 in. (300 mm) [18 in.
(460 mm) in Canada] above the normal snow line
and at least 12 in. (300 mm) above grade level.
d. Locate vent and combustion air terminals at
least 12 in. (300 mm) from any door, window, or
gravity inlet into the building.
e. Do not install vent terminal directly above
windows or doors.
IV. Venting A. General Guidelines (continued)
f. Locate bottom of vent terminal at least 3 ft. (900
mm)above any forced air inlet located within 10
ft. (3.0 m).
g. If window and/or air inlet is within 4 ft. (1.2 m)
of an inside corner, maintain at least 6 ft. (1.8 m)
spacing between terminal and adjoining wall of
inside corner.
h. Locate bottom of vent terminal at least 7 ft.
(2.1 m) above a public walkway.
i. Maintain minimum clearance of at least 4 ft.
(1.2 m) [3 ft. (900 mm)in Canada] horizontally
between vent terminal and gas meters, electric
meters, regulators, and relief equipment. Do
not install vent terminal above or below this
equipment.
Figure 10: Direct Vent - Vertical Terminations
j. Do not locate the vent terminal under decks or
similar structures.
k. Top of terminal must be at least 24 in. (600
mm) below ventilated eves, soffits, and other
overhangs. In no case may the overhang
exceed 48 in. (1200 mm). Where permitted
by the authority having jurisdiction and local
experience, the terminal may be located closer
to unventilated soffits. The minimum vertical
separation depends upon the depth of the soffit.
See Figure 6 for details.
l. Maintain minimum 12 in. (300 mm) horizontal
spacing between vent terminal and a building
corner.
m.Under certain conditions, water in the flue gas
may condense, and possibly freeze, on objects
around the terminal including on the structure
itself. If these objects are subject to damage by
flue gas condensate, they should be moved or
protected.
n. If possible, install the vent and combustion air
terminals on a wall away from the prevailing
wind. Reliable operation of this boiler cannot be
guaranteed if terminals are subjected to winds in
excess of 40 mph (64 km/hr).
o. Do not locate combustion air terminal in areas
that might contain combustion air contaminates,
such as near swimming pools.
p. For multiple boiler installations with horizontal
wall terminals, maintain minimum 12 in.
(300 mm) horizontal distance between adjacent
boiler vent terminals. Maintaining greater
spacing is recommended to avoid frost damage
to building surfaces where vent terminations are
placed.
Figure 11: Direct Vent - Vertical Terminations
with Sloped Roof
Extend vent/combustion air piping to maintain minimum vertical (‘X’) and minimum horizontal (‘Y’) distance
of 12 in. (300 mm) [18 in. (460 mm) Canada] from roof surface. Allow additional vertical (‘X’) distance for
expected snow accumulation.
21
IV. Venting (continued)
q. For multiple boiler installations with vertical
roof terminals, maintain minimum 12 in.
(300 mm) horizontal distance between adjacent
boiler vent terminals.
B. CPVC/PVC Venting
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 boiler) for near-boiler vent piping before
transitioning to Schedule 40 PVC pipe
(ASTM 2665) components for remainder of
vent system.
Use CPVC vent components within any
interior space where air cannot circulate
freely, including through vertical or
horizontal chase ways, inside a stud wall, in
closets, and through wall penetrations.
The use of cellular core PVC (ASTM
F891), cellular core CPVC or Radel
(polyphenolsulfone) is prohibited.
All condensate that forms in the vent must
be able to drain back to the boiler.
NOTICE
Do not exceed maximum vent/combustion
air system length. Refer to “2. Vent/
Combustion Air Piping” under “A. General
Guidelines” of this section for maximum
vent/combustion air system length.
Use only vent and combustion air terminals
and terminal locations shown in “3. Vent/
Combustion Air Terminals” under “A.
General Guidelines” of this section.
1.Components
22
a. See Table 11 for CPVC/PVC vent and
combustion air components included with boiler.
b. See Table 12 for CPVC/PVC installer provided
vent and combustion air components required for
optional horizontal snorkel terminals shown in
Figure 8.
c. See Table 13 for installer provided Ipex Low
Profile Vent Termination Kits.
d. See Table 14 for CPVC/PVC installer provided
vent and combustion air components required for
optional vertical roof terminals shown in Figure
10.
2. Field Installation of CPVC/PP/SS Vent
Connector
Refer to Figure 12 and following steps:
a. Position the vent connector and gasket onto
boiler rear panel and insert vent connector into
heat exchanger vent outlet.
b. Align vent connector plate and gasket clearance
holes with rear panel engagement holes. Be sure
combustion sample port is on left side looking
at rear of boiler. Then, secure the connector and
gasket to the panel with four mounting screws.
3. Near-Boiler Vent/Combustion Air Piping
Refer to Figure 13 and the following Steps:
a. Apply supplied dielectric grease to gasket inside
vent connector. The grease will prevent gasket
rupture when inserting vent pipe and gasket
deterioration due to condensate exposure.
b. Install provided Schedule 40 x 30 in. (760 mm)
long CPVC pipe into the vent section of the
connector with a slight twisting motion and
secure by tightening the clamp.
c. All CPVC vent components supplied with boiler
inside vent carton [Schedule 40 x 30 in. (760
mm) long CPVC pipe and Schedule 80 CPVC
90° Elbow] must be used for near-boiler piping
before transitioning to Schedule 40 PVC (ASTM
2665) pipe components for remainder of vent
system. The 30 in. (760 mm) long CPVC straight
pipe may be cut to accommodate desired vent
configuration provided both pieces are used
in conjunction with CPVC 90° Elbow before
any PVC components are used. Ensure that the
CPVC 90° Elbow is the first elbow used in the
vent system as it exits the boiler.
d. Apply PVC primer and cement and insert
Schedule 40 PVC combustion air pipe (installer
provided) into the combustion air connector with
a slight twisting motion.
4. System Assembly
WARNING
Asphyxiation Hazard. CPVC/PVC vent piping and
fittings rely on glued joints for proper sealing.
Follow all manufacturer instructions and
warnings when preparing pipe ends for joining
and using the primer and the cement.
a. Plan venting system to avoid possible contact
with plumbing or electrical wires. Start at
vent connector at boiler and work towards vent
termination.
IV. Venting B. CPVC/PVC Venting (continued)
WARNING
Asphyxiation Hazard. Apply supplied dielectric grease to gasket inside vent section of vent connector.
Failure to apply the grease could result in flue gas leaks from gasket rupture during vent pipe installation or
gasket deterioration due to condensate exposure.
Table 11: CPVC/PVC Vent & Air Intake Components Included With Boiler
Quantity
Vent & Air Intake Components
Models APX425C & APX525C
Standard 4 in. Intake/4 in. Vent Kit
includes
Models APX625C, APX725C & APX825C
Standard 4 in. Intake/6 in. Vent Kit
includes
1
1
2
1
1
1
1
2
1
1
Schedule 40 PVC Coupling
Schedule 40 PVC 90° Elbow
Stainless Steel Screen
30 in. Schedule 40 CPVC Pipe
Schedule 80 CPVC 90° Elbow
Table 12: CPVC/PVC Vent & Air Intake Components (Installer Provided) required for
Optional Horizontal Snorkel Termination
Quantity
Vent Components
APX425C & APX525C
Horizontal (Snorkel)
APX625C, APX725C & APX825C
Horizontal (Snorkel)
2
4
2
N/A
2
4
1
1
4 in. Intake/4 in. Vent
Schedule 40 PVC Pipe x up to 7 ft. (2.1 m) max. vertical run
Schedule 40 PVC 90° Elbow
Schedule 40 PVC Pipe x 6 in. (150 mm) min. horizontal run
Schedule 40 PVC Pipe x 9 in. (230 mm)min. horizontal run
4 in. Intake/6 in. Vent
Table 13: Components Required for Optional Ipex Low Profile Sidewall Termination
Ipex Part Number
Thermal Solutions
Part Number
3 in. Low Profile Termination Kit
196985
106415-03
4 in. Low Profile termination Kit
196986
106415-04
Description
Applicable to Boiler Sizes
425 (reduced dia.)
525 (reduced dia.)
425 (standard dia.)
525 (standard dia.)
625 (reduced dia.)
725 (reduced dia.)
825 (reduced dia.)
Table 14: CPVC/PVC Vent & Air Intake Components (Installer Provided) required for
Optional Vertical Roof Termination
Quantity
Vent Components
APX425C & APX525C
Vertical (Roof) Termination,
4 in. Intake/4 in. Vent
APX625C, APX725C & APX825C
Vertical (Roof) Termination,
4 in. Intake/6 in. Vent
Schedule 40 PVC Coupler
Schedule 40 PVC 90° Elbow
Schedule 40 CPVC Pipe x 6 in. (150 mm) min. horizontal
run
1
2
1
2
1
1
23
IV. Venting B. CPVC/PVC Venting (continued)
Figure 12: Field Installation CPVC/PP/SS Vent Connector
Figure 13: Near-Boiler Vent/Combustion Air Piping
b. Design the vent system to allow 3/8 in.
(9.5 mm) of thermal expansion per 10 ft. (3.0 m)
of CPVC/PVC pipe. Runs of 20 ft. (6.1 m) or
longer that are restrained at both ends must use
an offset or expansion loop. Refer to Figure 14
and Table 15.
c. All CPVC/PVC vent and combustion air
pipe joints must be cleaned with primer and
glued with cement. Follow all manufacturer
instructions and warnings when preparing pipe
ends for joining and using the primer and the
cement.
24
5. Horizontal Sidewall Termination
a. Standard Two-Pipe Termination
See Figure 7.
i. Vent Piping
Running PVC vent pipe inside Enclosures
and through Walls:
• PVC vent pipe must be installed in such
way as to permit adequate air circulation
around the outside of the pipe to prevent
internal wall temperature rising above
ANSI Z21.13 standard specified limit.
• Do not enclose PVC venting. Use higher
temperature rated CPVC pipe in enclosed
spaces or to penetrate combustible or
non-combustible walls.
IV. Venting B. CPVC/PVC Venting (continued)
Table 15: Expansion Loop Lengths
Nominal
Pipe
Dia. (In.)
3
4
6
Length of
Straight Run
Loop Length
“L”
ft.
m
in.
mm
20
30
40
50
60
6.1
53
65
75
84
92
1350
20
30
40
50
60
20
30
40
50
60
9.1
12
15
18
6.1
9.1
12
15
18
6.1
9.1
12
15
18
60
74
85
95
104
73
90
103
116
127
1650
1900
2130
2340
1520
1880
2159
2413
2642
1850
2290
2620
2950
3230
Figure 14: CPVC/PVC Expansion Loop and Offset
• PVC vent pipe may not be used
to penetrate combustible or noncombustible walls unless all following
three conditions are met simultaneously
(see Figure 15):
- The wall penetration is at least 66 in. (1680 mm) from the boiler as
measured along the vent
- The wall is 12 in. (300 mm) thick or
less
- An air space of at least of that shown in Figure 15 is maintained around outside of the vent pipe to provide air circulation
• If above three conditions cannot be
met simultaneously when penetrating
a combustible wall, use CPVC pipe for
wall penetration.
• Size and cut wall opening such that
a minimal clearance is obtained and
to allow easy insertion of vent pipe.
Figure 15: Wall Penetration Clearances
for PVC Vent Pipe
Wall thimbles for CPVC/PVC pipe are
available from Thermal Solutions: P/N’s
102180-01 (3 in.), 102181-01 (4 in.),
103419-01(6 in.).
• Apply sealant between vent pipe and wall
opening to provide weather-tight seal.
Sealant should not restrain the expansion
of the vent pipe.
• Install contractor provided optional trim
plate on wall outside surface to cover
wall opening (see Figure 15).
• Secure trim plate to wall with nails or
screws and seal ID and plate OD or
perimeter with sealant material.
25
IV. Venting B. CPVC/PVC Venting (continued)
Figure 16: Screen Installation
• Install screen and vent terminal
(supplied with boiler). See Figure 16 for
appropriate configuration details.
NOTICE
Methods of securing and sealing terminals to
the outside wall must not restrain the thermal
expansion of the vent pipe.
ii. Combustion Air Piping
• Size combustion air pipe wall penetration
opening to allow easy insertion of the
pipe.
• Install screen and combustion air
terminal (supplied with boiler). See
Figure 16 for appropriate configuration
details.
• Apply sealant between combustion
air pipe and wall opening to provide
weather-tight seal.
b. Optional Two-Pipe Snorkel Termination
See Figure 8.
This installation will allow a maximum of 7
ft. (2.1 m) vertical exterior run of the vent/
combustion air piping to be installed on the
CPVC/PVC horizontal venting application.
NOTICE
• Install screen and vent terminal
(supplied with boiler), see Figure 16 for
appropriate configuration.
• Brace exterior piping if required.
ii. Combustion Air Piping
• After penetrating wall, install a Schedule
40 PVC 90° elbow so that elbow leg is in
the up direction.
• Install maximum vertical run of 7 ft.
(2.1 m) of Schedule 40 PVC vent pipe.
See Figure 8.
• At top of air pipe length install another
PVC 90° elbow so that elbow leg is
opposite the building’s exterior surface.
• Install screen and combustion air
terminal (supplied with boiler). See
Figure 16 for appropriate configuration.
• Brace exterior piping if required.
6. Vertical Roof Termination
a. Standard Two-Pipe Termination
See Figures 10 and 11.
i. Vent Piping
• Install fire stops where vent passes
through floors, ceilings or framed walls.
The fire stop must close the opening
between the vent pipe and the structure.
• Whenever possible, install vent straight
through the roof. Refer to Figures 10 and
11.
- Size roof opening to maintain minimum clearance of 1 in. (25 mm)
from combustible materials.
- Extend vent pipe to maintain minimum vertical and horizontal distance of 12 in. (300 mm) from
roof surface. Allow additional
vertical distance for expected snow
accumulation. Provide brace as
required.
Exterior run to be included in equivalent vent/
combustion air lengths.
i.
26
Vent Piping
• After penetrating wall, install a Schedule
40 PVC 90° elbow so that the elbow leg
is in the up direction.
• Install maximum vertical run of 7 ft.
(2.1 m) of Schedule 40 PVC vent pipe.
See Figure 9.
• At top of vent pipe length install another
PVC 90° elbow so that elbow leg is
opposite the building’s exterior surface.
NOTICE
Vertical venting and combustion air roof
penetrations (where applicable) require the use
of roof flashing and storm collar, which are not
supplied with boiler, to prevent moisture from
entering the structure.
-
Install storm collar on vent pipe immediately above flashing. Apply Dow Corning Silastic 732 RTV Sealant or equivalent between vent pipe and storm collar to provide weather-tight seal.
IV. Venting (continued)
• Install screen and vent terminal
(supplied with boiler). See Figure 16 for
appropriate configuration.
• Brace exterior piping if required.
ii. Combustion Air Piping
• If possible, locate combustion air
termination on the same roof location as
the vent termination to prevent nuisance
boiler shutdowns. Combustion air
terminal may be installed closer to roof
than vent. Alternatively, boiler may be
installed with vertical roof vent terminal
and sidewall combustion air terminal.
• Size roof opening to allow easy insertion
of combustion air piping and allow
proper installation of flashing and storm
collar to prevent moisture from entering
the structure.
- Use appropriately designed vent flashing when passing through roofs. Follow flashing manufacturers’ instructions for installation procedures.
- Extend combustion air pipe to maintain minimum vertical and horizontal distance of 12 in.
(300 mm) from roof surface. Allow
additional vertical distance for
expected snow accumulation. Provide
brace as required.
- Install storm collar on combustion air pipe immediately above flashing. Apply Dow Corning Silastic 732 RTV Sealant or equivalent between combustion air pipe and storm collar to provide weather-tight seal.
• Install screen and combustion air
terminal (supplied with boiler). See
Figure 16 for appropriate configuration.
• Brace exterior piping if required.
C. Polypropylene Venting
NOTICE
Do not exceed maximum vent/combustion air
system length. Refer to “2. Vent/Combustion
Air Piping” under “A. General Guidelines” of
this section for maximum vent/combustion air
system length.
Use only vent and combustion air terminals
and terminal locations shown in “3. Vent/
Combustion Air Terminals” under “A. General
Guidelines” of this section.
WARNING
Asphyxiation Hazard. Follow these instructions
and the installation instructions included by
the listed polypropylene venting component
manufacturers, whichever applicable. Failure
to do so could cause products of combustion to
enter the building, resulting in severe property
damage, personal injury or death. Where a
conflict arises between a manufacturer’s
instructions and these instructions, the more
restrictive instructions shall govern.
Do not mix vent components or joining methods
for listed manufacturers.
Examine all components for possible shipping
damage prior to installation.
All condensate that forms in the vent must be
able to drain back to the boiler.
1. Components
a. Listed polypropylene vent system manufacturers
are shown in Table 16. It is the responsibility of
the installing contractor to procure polypropylene
vent system pipe and related components.
i. All listed polypropylene vent system
manufacturers comply with the requirements
of ULC-S636-08 ‘Standard for Type BH
Gas Venting Systems’.
ii. Centrotherm Eco Systems InnoFlue SW
Rigid Vent and Flex Flexible Vent, and
Z-Flex Z-Dens Single Wall Rigid Vent and
Flexible Vent comply with the requirements
of UL 1738 ‘Standard for Safety for Venting
Systems’.
b. See Table 17A for specific M&G Duravent
components.
c. See Table 17B for specific Centrotherm Eco
Systems components.
d. See Table 18 for specific Z-Flex Z-Dens
components.
2. Field Installation of Polypropylene Adapters
a. Vent Connector (see Figure 17)
i. No adapter is required for M&G DuraVent
PolyPro vent pipe unless vent diameter
is reduced per Table 8. See Table 17A
for M&G DuraVent boiler adapters for
reduced vent diameter. An adapter is always
required for Centrotherm InnoFlue vent
pipe and Z-Flex Z-Dens vent pipe. See
Table 17B for Centrotherm InnoFlue boiler
adapters and Table 18 for Z-Flex Z-Dens
boiler adapters.
27
IV. Venting C. Polypropylene Venting (continued)
ii. Install CPVC/PP/SS vent connector. Follow
instructions in “2. Field Installation of
CPVC/PP/SS Vent Connector” under “B.
CPVC/PVC Venting.”
iii. Apply provided dielectric grease to gasket
inside vent connector that will be in contact
with adapter.
iv. Push and twist adapter into vent system
connector until adapter bottoms out.
v. Tighten clamp to secure adapter in CPVC/
PP/SS vent connector.
b. Combustion Air Connector (see Figure 18)
i. No adapter is required if using PVC
combustion air pipe. An adapter is required
for both M&G DuraVent PolyPro (see Table
17A)Centrotherm InnoFlue (see Table
17B) and Z-Flex Z-Dens (see Table 18)
combustion air pipes.
ii. Insert adapter into combustion air connector.
Adapter has gasket to seal against
combustion air connector.
3. System Assembly
WARNING
Asphyxiation Hazard. Vent systems made
by listed PP vent system manufacturers rely
on gaskets for proper sealing. When these
vent systems are used, take the following
precautions:
• Make sure that gasket is in position and undamaged in the female end of the pipe.
• Make sure that both the male and female
pipes are free of damage prior to assembly.
• Only cut vent pipe as permitted by the
vent manufacturer in accordance with their
instructions. When pipe is cut, cut end
must be square and carefully de-burred prior
to assembly.
• Use locking band clamps at all vent pipe
joints.
a. Plan venting system to avoid possible contact
with plumbing or electrical wires. Start at
vent connector at boiler and work towards vent
termination.
b. Follow all manufacturer instructions and
warnings when preparing pipe ends for joining
and when assembling the vent/combustion air
system.
c. Use locking band clamps at all vent pipe joints.
See Figure 19 or Figure 20 for locking band
clamp installation.
28
NOTICE
The venting system must be free to expand
and contract and supported in accordance
with installation instructions included by the
original listed polypropylene venting component
manufacturers, whichever applicable.
Polypropylene pipe sections must be disengaged
1/4 to 5/8 in.
(6 mm to 16 mm) per joint to allow for thermal
expansion.
4. Terminations
a. For standard horizontal sidewall terminations, see
Figures 7 and 8. For vertical roof terminations,
see Figures 10 and 11. Use UV resistant
components listed in Tables 17A, 17B and 18.
b. If using M&G duravent PolyPro pipe, install
screens per Figure 16. Remove gasket inside
termination and install screen in place of gasket.
If using Centrotherm InnoFlue or Z-Flex Z-Dens
end pipe, screen fits onto end of pipe.
c. For low profile sidewall termination, see Figure
9. Use low profile termination listed in Table 13
and adapter kit listed in Tables 17A, 17B and 18.
5. Running Flexible Polypropylene Vent
(Liner) Through Unused Chimney Chase
WARNING
Asphyxiation Hazard. Flexible polypropylene
vent must be installed only in an UNUSED
chimney. A chimney, either single or multiple
flue type, is considered UNUSED when none
of the flues is being used for any appliance
venting. Where one of the multiple flues is
being used for an appliance venting, the flexible
vent installation is not permitted through any of
adjacent flues.
Table 16: Listed Polypropylene Vent System
Manufacturers
Make
M&G/DuraVent
Centrotherm Eco
Systems
Z-Flex Z-Dens
Model
PolyPro Single Wall Rigid Vent
PolyPro Flex Flexible Vent (APX425C and
APX525C)
InnoFlue SW Rigid Vent
Flex Flexible Vent (APX425C and APX525C)
Z-Dens Single Wall Rigid Vent
Z-Dens Flexible Vent (APX425C and
APX525C)
29
4 in.
(100 mm)
6 in.
(150 mm)
APX425C (standard dia. vent)
APX525C (standard dia. vent)
APX625C (reduced dia. vent)
APX725C (reduced dia. vent)
APX825C (reduced dia. vent)
APX625C (standard dia. vent)
APX725C (standard dia. vent)
APX825C (standard dia. vent)
6PPS-LB2 or
6PPS-LBC
4PPS-LB2 or
4PPS-LBC
3PPS-LB2 or
3PPS-LBC
Roof Termination:
(2) UV Resistant
90° Elbows
w/Screen
N/A
4PPS-ADL
N/A
N/A
Ipex Low
4PPS-R3L
No Adapter Needed
Pipe: 6PPS-12BL
Screen: 6PPS-BG
Pipe: 4PPS-12BL
Screen: 4PPS-BG
Pipe: 3PPS-12BL
Screen: 3PPS-BG
N/A
4PPS-FKL
3PPS-FKL
4 in.
(110 mm)
APX625C (reduced dia. vent)
APX725C (reduced dia. vent)
APX825C (reduced dia. vent)
IANS06 or
IADHC0606
IANS04
IANS03
N/A
ISAGL0404
ISAGL0404
with
ISRD0403
Boiler
Adapter
N/A
Elbow: ISEL0487UV
Screen: IASPP04
Elbow: ISELL0387UV
Screen: IASPP03
N/A
Elbow: ISEL0487UV
Screen: IASPP04
Elbow: ISELL0387UV
Screen: IASPP03
Combustion Air
Roof Termination:
Sidewall
Termination:
(2) UV Resistant
UV Resistant
90° Elbows w/
90° Elbow w/Screen
Screen
Pipe: ISEP06 or
ISEP0639
Screen: IASPP06
Pipe: ISEP04 or
ISEP0439
Screen: IASPP04
APX425C &
APX525C:
ISAAL0404;
APX625C,
APX725C &
APX825C:
ISAAL0606 with
ISRD0604
ISAAL0606
Pipe: ISEP03 or
ISEP0339
Screen: IASPP03
ISAAL0404 and
ISRD0403
Boiler Adapter
N/A
IFCK0425
or
IFCK0435
IFCK0325
or
IFCK0335
ISLTK06
ISLTK04
ISLTK03
Vent
Ipex Low
Profile Adapter
Sidewall* or Roof
Flex
Kit: Pipe Adapter
Termination: UV
Chimney
&
Resistant Straight
Lining Kit
Wall Plate
Pipe w/Screen
* Note: When using room air for combustion, use UV resistant 90° elbow or tee for sidewall vent termination. UV resistant 90° elbow part numbers: ISEL0387UV (3 in.), ISEL0487UV (4 in.), ISEL0687UV (6 in.).
UV resistant tee part numbers: ISTT0320 (3 in.), ISTT0420 (4 in.), ISTT0620 (6 in.).
See Centrotherm InnoFlue literature for other required component part numbers such as straight pipe, elbows, firestops, and vent supports.
APX625C (standard dia. vent)
6 in.
APX725C (standard dia. vent)
(160 mm)
APX825C (standard dia. vent)
3 in.
(80 mm)
APX425C (standard dia. vent)
APX525C (standard dia. vent)
APX625C (reduced dia. vent)
APX725C (reduced dia. vent)
APX825C (reduced dia. vent)
Boiler Model
Nominal
Pipe Joint
Pipe
Locking Band
Diameter
Clamp
Table 17B: Listed Polypropylene Pipe, Fittings and Terminations - Centrotherm Eco
N/A
4PPS-HLKL
3PPS-HLKL
Flex
Profile Termination
Sidewall* or Roof
Adapter Kit:
Termination: UV
Boiler Adapter
Resistant Straight Chimney
Pipe w/ Screen Lining Kit
Pipe Adapter &
Wall Plate
APX425C &
APX525C: No
Adapter Required;
Elbow: 4PPS-E90BL Elbow: 4PPS-E90BL
APX625C,
Screen: 4PPS-BG
Screen: 4PPS-BG
APX725C,
APX825C: 6PPSR5L with 5PPS-R4L
4PPS-ADL with Elbow: 3PPS-E90BL Elbow: 3PPS-E90BL
4PPS-R3L
Screen: 3PPS-BG
Screen: 3PPS-BG
Boiler
Adapter
Sidewall
Termination:
UV Resistant
90°Elbow
w/Screen
Vent
* Note: When using room air for combustion, use UV resistant 90° elbow or tee for sidewall vent termination. UV resistant 90° elbow part numbers: 3PPS-E90BL(3 in.), 4PPS-E90BL (4 in.), 6PPS-E90BL (6 in.).
UV resistant tee part numbers: 3PPS-TBL (3 in.), 4PPS-TBL (4 in.), 6PPS-TTBL (6 in.).
3 in.
(80 mm)
Nominal
Pipe Joint
Pipe
Locking Band
Diameter
Clamp
APX425C (reduced dia. vent)
APX525C (reduced dia. vent)
Boiler Model
Combustion Air
Table 17A: M&G DuraVent PolyPro Polypropylene Vent/Combustion Air System Components
IV. Venting C. Polypropylene Venting (continued)
6 in.
(150 mm)
APX625C standard dia. vent)
APX725C standard dia. vent)
APX825C standard dia. vent)
NOTICE
* Note: When using room air for combustion, use UV resistant 90° elbow or tee for sidewall vent termination. UV resistant 90° elbow part numbers: 2ZDE387UV (3 in.), 2ZDE487UV (4 in.), 2ZDE687UV (6 in.).
UV resistant tee part numbers: 2ZDTT3 (3 in.), 2ZDTT4 (4 in.), 2ZDTT6 (6 in.).
See Z-Flex Z-Dens literature for other required component part numbers such as straight pipe, elbows, firestops and vent supports.
(*) - Pipe Length
N/A
N/A
4 in.
(100 mm)
APX425C (standard dia. vent)
APX525C (standard dia. vent)
APX625C (reduced dia. vent)
APX725C (reduced dia. vent)
APX825C (reduced dia. vent)
2ZDLC6
Pipe: 2ZDP6(*)
Screen: 2ZDES6
2ZDCPVCCG6
Elbow: 2ZDE687
Screen: 2ZDES6
Elbow: 2ZDE687
Screen: 2ZDES6
2ZDCPVC4
N/A
2ZDFK425
or
2ZDFK435
Pipe: 2ZDP4(*)
Screen: 2ZDES4
Elbow: 2ZDE487UV
Screen: 2ZDES4
Elbow: 2ZDE487UV
Screen: 2ZDES4
2ZDCPVC4
3 in.
(80 mm)
APX425C (reduced dia. vent)
APX525C (reduced dia. vent)
2ZDLC4
2ZD144;
APX625C,
APX725C, &
APX825C:
2ZDCPVCCG6 with
2ZDR65 & 2ZDR54
N/A
2ZDCPVC4
with
2ZDR43
2ZDFK325
or
2ZDFK335
Pipe: 2ZDP3(*) UV
Screen: 2ZDES3
2ZD144 with
2ZDR43
Elbow: 2ZDE387UV
Screen: 2ZDES3
Elbow: 2ZDE387UV
Screen: 2ZDES3
Boiler
Adapter
2ZDLC3
Boiler
Adapter
Sidewall Termination:
UV Resistant 90°
Elbow w/Screen
Boiler Model
Vent
Combustion Air
Roof Termination:
(2) UV Resistant
90° Elbows
w/Screen
Pipe Joint
Locking
Band Clamp
Nominal
Pipe
Diameter
Table 18: Listed Polypropylene Pipe, Fittings and Terminations - Z-Flex Z-Dens
30
Sidewall * or Roof
Termination: UV
Resistant Straight
Pipe w/Screen
Flex
Chimney
Lining Kit
Ipex Low Profile
Termination
Adapter &
Wall Plate
IV. Venting C. Polypropylene Venting (continued)
Pressure drop for flexible polypropylene liner
is 20% greater than from rigid pipe. Multiply
measured flexible polypropylene liner length by
1.2 to obtain equivalent length.
Maximum equivalent length of flexible
polypropylene liner is 48 ft. (14.6 m).
a. Models APX425C and APX525C are listed for
vertical venting by installing flexible vent in an
UNUSED masonry chimney/chase and supplying
combustion air through a separate wall or roof
combustion air terminal.
b. Refer to Figure 21 for details of chimney chase
installation.
c. Flexible polypropylene pipe must be treated
carefully and stored at temperatures higher than
41°F (5°C).
d. Do not bend or attempt to install flexible pipe if
it has been stored at lower ambient temperature
without allowing the pipe to warm up to a higher
temperature first.
WARNING
Asphyxiation Hazard. Bending or attempting
to install flexible pipe if it has been stored at
ambient temperature below 41°F (5°C) will
cause material to become brittle and lead to
cracks, resulting in flue gas leaks.
Do not install flexible polypropylene pipe
at an angle greater than 45 degrees from
vertical plane when used for combustion
product venting. Failure to do so will result
in improper condensate drainage towards
the boiler and possible subsequent vent
pipe blockage.
e. When flexible polypropylene pipe (liner) is used
for combustion product venting, it must not be
installed at an angle greater than 45 degrees from
vertical plane. This will insure proper condensate
flow back towards the boiler.
f. When flexible polypropylene pipe (liner) is used
for combustion air supply to a boiler, the pipe
(liner) can be installed in vertical or horizontal
position.
g. Follow flexible polypropylene pipe (liner)
manufacturer specific installation instructions
regarding application/listing, permits, minimum
clearances to combustibles, installation details
(proper joint assembly, pipe support and routing,
gasket and fitting installation, optional tooling
availability/usage, routing through masonry
IV. Venting C. Polypropylene Venting (continued)
chimney for combustion product venting or,
combination of combustion product venting and
combustion air supply).
h. When there is a conflict between flexible
polypropylene pipe (liner) manufacturer
installation instructions and Apex boiler
Installation, Operating and Service Instructions,
the more restrictive instructions shall govern.
Figure 19: Locking Band Clamp Installation,
M&G DuraVent or Centrotherm InnoFlue
Figure 17: Field Installation of
Polypropylene Vent Adapter
Figure 20: Alternate Locking Band Clamp
Installation, M&G DuraVent
Figure 18: Field Installation of Polypropylene
Combustion Air Adapter
31
IV. Venting C. Polypropylene Venting
Venting of Other Appliances (or Fireplace)
into Chase or Adjacent Flues Prohibited!
Figure 21: Flexible Vent in Masonry Chimney with Separate Combustion Air Intake
32
IV. Venting (continued)
D. Stainless Steel Venting
WARNING
Asphyxiation Hazard. Follow these instructions
and the installation instructions included by
the original stainless steel venting component
manufacturers, Heat Fab, M&G/DuraVent or
Z-Flex, whichever applicable. Failure to do so
could cause products of combustion to enter the
building, resulting in severe property damage,
personal injury or death. Where a conflict arises
between Heat Fab, M&G/DuraVent or Z-Flex
instructions and these instructions, the more
restrictive instructions shall govern.
Do not mix vent components from listed
manufacturers.
Examine all components for possible
shipping damage prior to installation.
All condensate that forms in the vent must be
able to drain back to the boiler.
NOTICE
b. Alternate listed stainless steel vent system
manufacturers and components are shown in
Tables 20 and 21.
c. Where the use of “silicone” is called for in the
following instructions, use GE RTV 106 or
equivalent for the vent collar. Seal galvanized
combustion air piping sections with any generalpurpose silicone sealant such as GE RTV102.
Seal PVC combustion air piping sections with
PVC cement.
d. Do not drill holes in vent pipe.
2. Field Installation of Stainless Steel Vent
Adapter (see Figure 22)
a. No adapter is required for stainless steel vent
pipe unless vent diameter is reduced per Table 8.
See Table 19, 20, or 21 for adapters for reduced
vent diameter.
Table 19: Thermal Solutions (Heat Fab)
Vent System Components
(Stainless Steel, 4 in. only)
Component
Do not exceed maximum vent/combustion
air system length. Refer to “2. Vent/
Combustion Air Piping” under “A. General
Guidelines” in this section for maximum
vent/combustion air system length.
Use only vent and combustion air terminals
and terminal locations shown in “3. Vent/
Combustion Air Terminals” under “A.
General Guidelines” of this section.
1.Components
a. For use on models APX425C and APX525C,
Thermal Solutions offers size 4 in. vent pipe and
fittings shown in Table 19. It is the responsibility
of the installing contractor to procure stainless
steel vent system pipe and related components.
Part Number, 4 in.
(100 mm)
no adapter required
Boiler Adapter
Sidewall * or Roof Termination:
Straight
102680-02
Termination w/Screen
Straight Pipe, 1 ft. (0.3 m)
100176-01
Straight Pipe, 3 ft. (0.9 m)
100177-01
Straight Pipe, 5 ft. (1.5 m)
100178-01
Straight Pipe, Adjustable
100179-01
1.06-1.64 ft. (0.3 m to 0.5 m)
90° Elbow
100180-01
45° Elbow
100181-01
Horizontal Drain Tee
100182-01
Vertical Drain Tee
100183-01
Single Wall Thimble
100184-01
* Note: when using room air for combustion, use tee for
sidewall vent termination.
Tee part number: 8116313 (4 in.).
Table 20: M&G DuraVent FasNSeal Stainless Steel Vent System Components, Single Wall
Boiler Model
Nominal Pipe
Diameter
Boiler Adapter
Sidewall * or Roof Termination:
Straight Termination w/Screen
Wall Thimble
APX425C (reduced dia. vent)
3 in. (80 mm)
FS0403TR
FSBS3
FSWT3
APX525C (reduced dia. vent)
APX425C (standard dia. vent)
APX425C & APX525C:
APX525C (standard dia. vent)
No Adapter Required;
FSBS4
FSWT4
4 in. (100 mm)
APX625C (reduced dia. vent)
APX625C, APX725C,
APX725C (reduced dia. vent)
APX825C: FS0604TR
APX825C (reduced dia. vent)
APX625C (standard dia. vent)
APX725C (standard dia. vent)
6 in. (150 mm)
No Adapter Required
FSBS6 (23° angle)
FSWT6
APX825C (reduced dia. vent)
Note: When using room air for combustion, use tee for sidewall vent termination. Termination tee part numbers: FSTT3 (3 in.),
FSTT4 (4 in.) FSTT6 (6 in.)
See M&G DuraVent FasNSeal literature for other required component part numbers such as straight pipe, elbows, firestops, and vent supports.
33
IV. Venting D. Stainless Steel Venting (continued)
Table 21: Z-Flex, Z-Vent (SVE Series III, Z-Vent III) Stainless Steel Vent System Components, Single Wall
Boiler Model
Nominal Pipe Diameter
Boiler Adapter
Sidewall * or Roof Termination:
Straight Termination w/Screen
Wall Thimble
APX425C (reduced dia. vent)
3 in. (80 mm)
2SVSR0403
2SVSTPX03
2SVSWTF03
APX525C (reduced dia. vent)
APX425C & APX525C:
APX425C (standard dia. vent)
No Adapter ReAPX525C (standard dia. vent)
2SVSTPX04
2SVSWTF04
quired; APX625C,
4 in. (100 mm)
APX625C (reduced dia. vent)
APX725C, APX825C:
APX725C (reduced dia. vent)
2SVSR0604
APX825C (reduced dia. vent)
APX625C (standard dia. vent)
APX725C (standard dia. vent)
6 in. (150 mm)
No Adapter Required
2SVSTPX06
2SVSWTF06
APX825C (standard dia. vent)
* Note: When using room air for combustion, use 90° elbow or tee for sidewall vent termination. Termination elbow part numbers: 2SVSTEX0390
(3 in.), 2SVSTEX0490 (4 in.). Termination tee part numbers: 2SVSTTX03 (3 in.), 2SVSTTX04 (4 in.), 2SVSTTX06 (6 in.).
See Z-Flex literature for other required component part numbers such as straight pipe, elbows, firestops, and vent supports.
b. Install CPVC/PP/SS vent connector. Follow
instructions in “2. Field Installation of CPVC/
PP/SS Vent Connector” under “B. CPVC/PVC
Venting.”
c. Apply provided dielectric grease to gasket inside
vent connector that will be in contact with
adapter.
d. Push and twist adapter into vent system
connector until adapter bottoms out.
e. Tighten clamp to secure adapter in CPVC/PP/SS
vent connector.
3. System Assembly
WARNING
Asphyxiation Hazard. Vent systems made
by Heat Fab, M&G / DuraVent and Z-Flex rely
on gaskets for proper sealing. When these
vent systems are used, take the following
precautions:
• Make sure that gasket is in position and
undamaged in the female end of the pipe.
• Make sure that both the male and female
pipes are free of damage prior to assembly.
• Only cut vent pipe as permitted by the
vent manufacturer in accordance with their
Instructions. When pipe is cut, cut end must
be square and carefully de-burred prior to
assembly.
a. Plan venting system to avoid possible contact
with plumbing or electrical wires. Start at
vent connector at boiler and work towards vent
termination.
b. Follow all manufacturer instructions and
warnings when preparing pipe ends for joining
and when assembling the vent/combustion air
system.
34
Figure 22: Field Installation of Stainless
Steel Vent Adapter
NOTICE
The venting system must be free to expand
and contract and supported in accordance
with installation instructions included by the
original stainless steel venting component
manufacturers, Heat Fab, M&G / DuraVent or
Z-Flex, whichever applicable.
c. On horizontal pipe sections, orient all welded
seams at the 12:00 position. Do not place
longitudinal welded seams at the bottom of
horizontal sections of vent pipe.
d. Assemble the combustion air system using either
galvanized or PVC pipe.
i. If PVC piping is used, use PVC cement
to assemble the PVC intake system
components. See “B. CPVC/PVC Venting”
for combustion air pipe installation
instructions.
ii. If galvanized piping is used, use at least two
sheet metal screws per joint. Seal outside of
all joints.
IV. Venting (continued)
4. Horizontal Sidewall Vent Termination
ii. Combustion Air Termination
• After penetrating wall, install a 90°
elbow so that the elbow leg is in the up
direction.
• Install maximum vertical run of 7 ft.
(2.1 m) of combustion air pipe as shown
in Figure 8.
• At top of vent pipe length install another
90° elbow so that the elbow leg is
opposite the building’s exterior surface.
• Install screen and horizontal vent
terminal.
• Brace exterior piping if required.
a. Standard Two-Pipe Termination
See Figure 7.
i. Vent Termination
• Use components listed in Table 19, 20 or
21.
NOTICE
The joint between the terminal and the last piece
of pipe must be outside of the building.
• Male end of terminal will fit into female
end of any of the listed stainless vent
systems.
• Apply a heavy bead of silicone to the
male end of the terminal before inserting
it into the last piece of pipe. Orient the
terminal so that the seam in the terminal
is at 12:00.
• Smooth the silicone over the seam
between the terminal and the last piece
of pipe, applying additional silicone if
necessary to ensure a tight seal.
• Allow the silicone to cure per the silicone
manufacturer’s instructions before
operating the boiler.
ii. Combustion Air Termination
• Use a 90° elbow directed downward..
• Install a screen in the inlet terminal. Use
a screen having 1/2 in. x 1/2 in. (13 mm
x 13 mm) mesh.
b. Optional Two-Pipe Snorkel Termination
See Figure 8.
This installation will allow a maximum of
7 ft. (2.1 m) vertical exterior run of the vent/
combustion air piping to be installed on the
approved AL29-4C stainless steel horizontal
venting application.
i. Vent Termination
• After penetrating wall, install the
appropriate manufacturer’s 90° elbow so
that the elbow leg is in the up direction.
• Install maximum vertical run of 7 ft.
(2.1 m) of appropriate manufacturer’s
vent pipe as shown in Figure 8.
• At top of vent pipe length install another
appropriate manufacturer’s 90° elbow
so that the elbow leg is opposite the
building’s exterior surface.
• Install horizontal vent terminal.
• Brace exterior piping if required.
5. Vertical Vent Termination
a. Standard Two-Pipe Termination
See Figures 10 and 11.
i.
Vent Termination
• Use the terminal supplied by the vent
system manufacturer shown in Table
19, 20 or 21. Follow manufacturer’s
instructions to attach terminal to vent
system.
ii. Combustion Air Termination
• Install vertical combustion air terminal.
Vertical combustion air terminal consists
of a 180° bend (comprised of two 90°
elbows) as shown in Figure 10.
• Install screen in the combustion air
terminal. Use a screen having 1/2 in. x
1/2 in. (13 mm x 13 mm) or larger mesh.
E. Optional Room Air for Combustion
1. General Guidelines
a. Room air is optional for commercial applications.
Room air uses one pipe to expel products of
combustion directly outdoors with combustion
air supplied from boiler room or enclosure.
Direct vent is recommended for residential
applications. Direct vent uses two pipes, one to
expel products of combustion directly outdoors
and one to supply combustion air to the boiler
directly from outdoors. See preceding sections A
through D for direct vent instructions.
b. Avoid combustion air contaminants in the boiler
room. See Table 4. Permanently remove any
contaminants found in the boiler room. If
contaminants cannot be removed, do not use
room air for combustion.
35
IV. Venting (continued)
3. Terminations
WARNING
Sources of combustion air contaminants,
including chlorines, chlorofluorocarbons
(CFC’s), petroleum distillates, detergents, volatile
vapors or other chemicals must not be present in
the boiler room. If any of these contaminants is
present, severe boiler corrosion and failure will
result.
2. Outdoor Openings to Boiler Room
a. Provide combustion and ventilation air to the
boiler room or enclosure. Follow the National
fuel Gas Code, ANSI Z223.1, or, in Canada,
Installation Code for Gas Burning Appliances
and Equipment, CGA Standard B149 Code as
well as all applicable local codes. Use one of the
following two methods.
b. Two Permanent Openings Method: Provide
two permanent openings, once within 12 in. (300
mm) of the top of the enclosure and one within
12 in. (300 mm) of the bottom of the enclosure.
Openings must communicate directly, or by
ducts, with the outdoors or spaces that freely
communicate with the outdoors, as follows:
i. Direct communication or through vertical
ducts: minimum free area of each opening
shall be 1 in.2/4000 Btu/hr (550 mm2/kW) of
total input rating of all appliances within the
enclosure.
ii. Horizontal ducts: minimum free area of
each opening shall be 1 in.2/2000 Btu/hr
(1100 mm2/kW) of total input rating of all
appliances within the enclosure.
c. One Permanent Opening Method: Provide
one permanent opening, commencing within 12
in. (300 mm) of the top of the enclosure. The
opening shall communicate through a vertical
or horizontal duct to the outdoors or spaces that
freely communicate with the outdoors and shall
have a minimum free area of the following:
i. 1 in.2/3000 Btu/hr (700 mm2/kW) of total
input rating of all appliances located within
the enclosure.
ii. Not less than the sum of the areas of all vent
connectors in the space.
d. Motorized Louvers or Dampers: Motorized
louvers or dampers must be interlocked with
the boiler to allow ignition and firing of the
burner only when louvers are in the fully-open
position. Wire the interlock to the Auto Reset
External Limit connections. See Section VIII
“Electrical”.
36
a. For standard horizontal sidewall terminations,
see Figures 7 and 8. When using room air for
combustion, use 90° elbow or tee for sidewall
vent termination.
NOTICE
Use 90° elbow or tee for horizontal sidewall vent
termination when using room air for combustion.
b. For vertical roof terminations, see Figures 10 and
11.
F. Removing the Existing Boiler
When an existing boiler is removed from a common
venting system, the common venting system is likely
to be too large for proper venting of the remaining
appliances. At the time of removal of an existing
boiler, the following steps shall be followed with each
appliance remaining connected to the common venting
system placed in operation, while the other appliances
remaining connected to the common venting system are
not in operation.
1. Seal any unused openings in the common venting
system.
2. Visually inspect the venting system for proper
size and horizontal pitch and determine there is no
blockage or restriction, leakage, corrosion, and other
deficiencies which could cause an unsafe condition.
3. Insofar as is practical, close all building doors and
windows and all doors between the space in which
the appliances remaining connected to the common
venting system are located and other spaces of the
building. Turn on clothes dryers and any appliance
not connected to the common venting system.
Turn on any exhaust fans, such as range-hoods and
bathroom exhausts, so they will operate at maxi­mum
speed. Do not operate a summer exhaust fan. Close
fireplace dampers.
4. Place in operation the appliance being inspected.
Follow the Lighting (or Operating) Instructions.
Adjust thermo­stat so appliance will operate
continuously.
5. Test for spillage at the draft hood relief opening after
5 minutes of main burner operation. Use the flame
of a match or candle, or smoke from a cigarette,
cigar or pipe.
6. After it has been determined that each appliance
remain­ing connected to the common venting system
properly vents when tested as outlined above, return
doors, win­dows, exhaust fans, fireplace dampers and
any other gas burning appliance to their previous
conditions of use.
IV. Venting (continued)
7. Any improper operation of the common venting
system should be corrected so the installation
conforms with the National Fuel Gas Code, ANSI
Z223.1/NFPA 54 and/or the Natural Gas and
Propane Installation Code, CAN/CSA B149.1.
When resizing any portion of the common venting
system, the common venting system should be
resized to approach the minimum size as determined
using the appropriate tables in Part II in the National
Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or the
Natural Gas and Propane Installation Code, CAN/
CSA B149.1.
Au moment du retrait d’une chaudière existante, les
mesures suivantes doivent être prises pour chaque
appareil toujours raccordé au système d’evacuation
commun et qui fonctionne alors que d’autres appareils
toujours raccordés au système d’évacuation ne
fonctionnent pas:
1. Sceller toutes les ouvertures non utilisées du
système d’évacuation.
2. Inspecter de façon visuelle le système d’évcuation
pour déterminer la grosseur et l’inclinaison
horizontale qui conviennent et s’assurer que le
système est exempt d’obstruction, d’étranglement,
de fuite, de corrosion et autres défaillances qui
pourraient présenter des risques.
3. Dans la mesure du possible, fermer toutes les
portes et les fenêtres du bâtiment et toutes les
portes entre l’espace où les appareils toujours
raccordés au système d’évacuation sont installés
et les autres espaces du bâtiment. Mettre en
marche les sécheuses, tous les appareils non
raccordés au système d’évacuation commun
et tous les ventilateurs d’extraction comme les
hottes de cuisinière et les ventilateurs des salles de
bain. S’assurer que ces ventilateurs fonctionnent
à la vitesse maximale. Ne pas faire fonctionner
les ventilateurs d’été. Fermer les registres des
cheminées.
4. Mettre l’appareil inspecté en marche. Suivre les
instructions d’allumage. Régler le thermostat de
façon que l’appareil fonctionne de façon continue.
5. Faire fonctionner le brùleur principal pendant 5
min ensuite, déterminer si le coupe-tirage déborde
à l’ouverture de décharge. Utiliser la flamme d’une
allumette ou d’une chandelle ou la fumée d’une
cigarette, d’un cigare ou d’une pipe.
6. Une fois qu’il a été déterminé, selon la méthode
indiquée ci-dessus, que chaque appareil raccordé
au système d’évacuation est mis à l’air libre de
façon adéquate. Remettre les portes et les fenêtres,
les ventilateurs, les registres de cheminées et les
appareils au gaz à leur position originale.
7. Tout mauvais fonctionnement du système
d’évacuation commun devrat être corrigé de façon
que l’installation soit conforme au National Fuel
Gas Code, ANSI Z223.1/NFPA 54 et (ou) aux
codes d’installation CAN/CSA-B149.1. Si la
grosseur d’une section du système d’évacuation
doit être modifiée, le système devrait être modifié
pour respecter les valeurs minimales des tableaux
pertinents de l’appendice F du National Fuel Gas
Code, ANSI Z223.1/NFPA 54 et (ou) des codes
d’installation CAN/CSA-B149.1.
G. Multiple Boiler Installation Venting
1. Vent Piping and Terminations
a. Multiple boiler vent terminations are shown in
Figure 23.
b. Each individual boiler must have its own vent
pipe and vent terminal. Refer to Paragraphs A
through F (as applicable) for individual boiler
vent guidelines and options.
WARNING
Asphyxiation Hazard. No common manifold
venting (vent piping and vent terminals) is
permitted.
c. Do not exceed the individual boiler maximum
vent length listed in Table 8.
d. For horizontal sidewall terminations, maintain
at least 12 in. (300 mm) minimum horizontal
distance between any adjacent individual boiler
vent terminations. Additional horizontal spacing
between any adjacent individual boiler vent
terminations as well as extending the distance
from building surfaces to vent termination end
are recommended to avoid frost damage to
building surfaces where vent terminations are
placed.
NOTICE
Installing multiple individual boiler vent
terminations too close together may result in
combustion product water vapor condensation
on building surfaces, where vent terminations
are placed, and subsequent frost damage.
To avoid/minimize frost damage, extend
the distance from building surfaces to vent
termination end and increase the horizontal
distance between adjacent vent terminations.
e. Individual boiler sidewall vent terminals must be
placed at least 12 in. (300 mm) [18 in. (460 mm)
in Canada] above the ground plus the expected
snow accumulation.
37
IV. Venting G. Multiple Boiler Installation Venting (continued)
f. Multiple individual boiler vertical vent pipes
may be piped through a common conduit or
chase so that one roof penetration may be made.
g. For vertical roof terminations, maintain at
least 12 in. (300 mm) minimum horizontal
distance between adjacent individual boiler vent
terminations.
2. Combustion Air Piping
a. Multiple boiler combustion air terminations are
shown in Figure 23.
38
b. Each individual boiler must have own
combustion air pipe and terminal. Refer to
Paragraphs A through F (as applicable) for
individual boiler combustion air guidelines and
options.
c. Do not exceed the individual boiler maximum
combustion air pipe length listed in Table 8.
d. If possible, locate vent and combustion air
terminals for an individual boiler on the same
wall to prevent nuisance shutdowns. If not,
an individual boiler may be installed with a
roof vent terminal and sidewall combustion air
terminal.
39
Figure 23: Multiple Boiler Direct Vent Termination
IV. Venting G. Multiple Boiler Installation Venting (continued)
V. Condensate Disposal
A. Condensate Trap and Drain Line
1. All condensate which forms in the boiler or vent
system collects in the sump under heat exchanger
and leaves the boiler through factory installed
condensate trap.
2. The trap allows condensate to drain from sump
while retaining flue gases in the boiler. The trap
has factory installed overflow switch, which shuts
down the boiler in the event the drain line becomes
obstructed, preventing proper condensate removal.
Refer to Section XI “Service and Maintenance” for
condensate trap and condensate overflow switch
removal and replacement procedure, if required.
3. Note the following when disposing of the
condensate:
a. Condensate is slightly acidic, typical pH around
3.5 - 4.5. Do not use metallic pipe or fittings in
the condensate drain line. Do not route the drain
line through areas that could be damaged by
leaking condensate.
b. Do not route or terminate the condensate drain
line in areas subject to freezing temperatures.
c. If the point of condensate disposal is above the
trap, a condensate pump is required to move
the condensate to the drain. Select a condensate
pump approved for use with condensing
furnaces. If overflow from the pump would
result in property damage, select a pump with an
overflow switch. Wire this switch in series with
installer provided external high limit, to shut off
the boiler, and, if desired, in series with installersupplied alarm, to trigger an alarm in the event
of overflow.
d. Do not attempt to substitute another trap for one
provided with the boiler.
e. In order for boiler to work properly, the boiler
must be leveled during installation.
4. The condensate trap connection is located at
boiler left side, below inlet and outlet water pipe
connections. Refer to Figures 1, 2, 3 and 24.
5. Condensate trap must be filled up with water,
prior to boiler start-up and before connecting any
condensate line to the boiler to insure combustion
products cannot escape from operating boiler. To fill
the trap, inject water in the amount of 1 cup (240ml)
through condensate trap connection. Do not overfill
the trap.
6. Install tee for condensate overflow and vent as
shown in Figure 24.
40
WARNING
Asphyxiation Hazard. Failure to fill the
condensate trap with water prior to boiler startup could cause flue gas to enter the building,
resulting in personal injury or death.
7. If any additional condensate drain line is needed,
construct the extension from PVC or CPVC
Schedule 40 pipe. The factory supplied ¾ in. x 5-5/8
in. long PVC coupling, located in the miscellaneous
parts carton, must be used to connect drain line to
the condensate trap. Do not over tighten coupling
compression nuts when connecting drain line and
condensate trap.
8. Size condensate drain line, pump and neutralizer
(if using other than manufacturer neutralizer kit) to
accommodate maximum condensate flow shown in
Table 22 “Maximum Condensate Flow”.
Table 22: Maximum Condensate Flow
Boiler
Model
*Maximum Condensate Flow,
GPH
APX425C
4.5
APX525C
5.6
APX625C
7.0
APX725C
8.1
APX825C
9.0
*Assumes 100% of water in fuel condenses.
WARNING
Asphyxiation Hazard. Failure to install the
condensate drain in accordance with the above
instructions could cause flue gas to enter the
building, resulting in personal injury or death.
NOTICE
Boiler condensate is corrosive. Route
condensate drain line in a manner such
that any condensate leakage will not cause
property damage.
Some jurisdictions may require that
condensate be neutralized prior to disposal.
Use materials approved by the authority
having jurisdiction.
V. Condensate Disposal (continued)
Figure 24: Condensate Trap and Drain Line
B. Condensate Neutralizer Installation
1. Some jurisdictions may require that the condensate
be neutralized before being disposed of. Follow
local codes pertaining to condensate disposal.
2. A condensate neutralizer kit (P/N 101867-01) is
available as optional equipment. Follow local codes
and instructions enclosed with the kit for condensate
neutralizer installation.
3. Limestone chips will get coated by neutral salts
(product of chemical reaction between limestone
and acidic condensate) and lose neutralizing
effectiveness over time. Therefore, periodic
condensate neutralizer maintenance and limestone
chip replacement must be performed. A pH test or
acid test kits are available from HVAC/plumbing
distributors and should be used to measure
condensate acidity before/after neutralizer thus
indicating a need for service and chip replacement.
41
VI. Water Piping and Trim
NOTICE
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 appliance operation and service (circulator replacement, etc.).
Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components, and
can lead to boiler failure. Thermal Solutions’ Standard Warranty does not cover problems caused by
oxygen contamination of boiler water or scale (lime) build-up caused by frequent addition of water.
Do not fill boiler with softened water to prevent chloride contamination.
Installation is not complete unless a safety relief valve is installed into the tapping located on left side
of appliance or the supply piping.
A. Installation of Factory Supplied Piping and
Trim Components
1. Install provided components per Figure 25 for
APX425C or Figure 26 for APX525C through
APX825C. Rear tapping is return/inlet. Front
tapping (middle on APX425C) is supply/outlet.
Piping and trim components are located in
miscellaneous parts carton shipped with the
boiler.
a. Safety Relief Valve – Install on tee off 3/4 in.
NPT tapping on APX425C or on tee off supply
tapping on APX525C through APX825C. Use
42
provided 10 in. long nipple to locate valve above
heat exchanger top.
b. Drain Valve – Install on tee off 3/4” NPT tapping
on APX425C or on tee off supply tapping on
APX525C through APX825C.
c. Temperature and Pressure Gauge – Install on
supply piping.
d. Flow Switch – Install on supply piping. Use
provided tee with 1 in. NPT outlet. Use correct
paddle per Table 23. Refer to Section VIII
“Electrical” for flow switch wiring.
e. Install drain valve into tee bottom outlet.
Figure 25: Factory Supplied Piping and Trim Installation - APX425C
VI. Water Piping and Trim (continued)
i.
Space heating only - refer to Tables 25 and
26 and Figure 28 “Near Boiler Piping Heating Only” as applicable.
ii. Space heating plus indirect water heater(s)
– refer to Tables 25 and 26 and Figure 29
“Near Boiler Piping - Heating Plus Indirect
Water Heater” as applicable.
Table 23: Flow Switch Paddle Application
Boiler
Flow Switch
Paddle Marking
APX425C
1
APX525C
E
APX625C
3
APX725C
1
APX825C
1
iii. If piping indirect water heater off boiler (see
Figure 30), be sure that indirect water heater
and domestic hot water circulator are sized
to maintain flow through boiler within limits
shown in Table 24.
B. Piping System To Be Employed.
Apex boilers are designed to operate in a closed loop
pressurized system. Minimum pressure in the boiler
must be 14.5 psi (100 kPa). Proper operation of the
Apex boiler requires that the water flow through the
boiler remain within the limits shown in Table 24 any
time the boiler is firing.
NOTICE
Failure to maintain the flow through boiler within
specified limits could result in erratic operation
or premature boiler failure.
1. Near boiler piping must isolate Apex boiler
from system piping via closely spaced tees to
insure specified flow range through boiler any
time the boiler is firing.
NOTICE
Where it is not possible to install a separate
boiler loop, the system circulator must be
sized to ensure that the flow through boiler
stays within the defined parameters to prevent
overheating when the boiler is fired at it’s full
rated input. Install a flow meter to measure the
flow, or fire the boiler at full rate and ensure the
boiler DT does not exceed 35°F (19°C).
2. Direct connection of Apex boiler to heating
system, similar to a conventional boiler, is
NOT RECOMMENDED because:
a. The flow rate through system must be the same
as through boiler and fall within limits specified
in Table 24.
b. Pressure drop through entire system must be
known, added to pressure drop through boiler,
and a circulator selected to provide required flow
at total calculated pressure drop.
c. It is often very difficult to accurately calculate
the pressure drop through the system.
d. In replacement installations, it may be nearly
impossible to get an accurate measurement of
piping amount and number of fittings in the
system. If system is zoned, the system flow rate
may drop well below recommended minimum
flow when only a single zone is calling for heat.
a. The flow rate through the isolated near-boiler
loop is maintained by installer supplied
boiler circulator. See Tables 25 and 26 for
recommended circulators.
b. The flow rate through the isolated near-boiler
loop is completely independent of the flow rate
through the heating system loop(s).
c. The flow rate through the heating system loop(s)
is controlled by installer sized/provided system
loop circulator(s).
d. This piping arrangement can be used either for
space heating-only applications or space heating
with indirect water heater(s) applications.
Table 24: Flow Range Requirement Through Boiler
Boiler
Model
Supply
Return
Connection Connection
(in.)
(in.)
DT= 35°F
Boiler
Minimum
Head
Required
Loss
Flow (GPM)
(ft.)
ΔT = 30°F
ΔT = 25°F
ΔT = 20°F
Required Boiler Required
Boiler
Maximum
Boiler
Flow
Head
Flow Head Loss Required
Head
(GPM) Loss (ft.) (GPM)
(ft.)
Flow (GPM) Loss (ft.)
APX425C
1-1/2
1-1/2
21.5
6.1
25.1
7.9
30.2
10.8
37.7
15.9
APX525C
2
2
27.7
5.2
32.3
6.8
38.8
9.3
48.5
13.6
APX625C
2
2
33.9
4.7
39.6
6.1
47.5
8.4
59.4
12.4
APX725C
2
2
39.4
6.0
45.9
7.9
55.1
10.9
68.9
16.1
APX825C
2
2
43.4
5.9
50.7
7.8
60.8
10.8
76.0
16.1
Notes: Required Flow = Output*1000/(500*ΔT), where flow rate is in GPM, output is in MBH, and ΔT is in °F
Outputs for specific boiler models are provided in Table 3. See also Tables 25 and 26 for near boiler piping sizing. Using boiler antifreeze
will result in increased fluid density and may require larger circulators.
43
44
2
2
2
2
APX525C
APX625C
APX725C
APX825C
2½
2
2
2
2
43.4
39.4
33.9
27.7
21.4
Flow
(GPM)
6.4
7.1
5.5
5.8
6.4
Boiler &
Piping
Head Loss
(ft.)
DT=35°F
2400-60
2400-60
2400-60
0012
0014
Circulator
Model
50.7
45.9
39.6
32.3
25.0
Flow
(GPM)
8.5
9.4
7.2
7.5
8.3
Boiler &
Piping
Head Loss
(ft.)
DT=30°F
2400-65
2400-65
2400-60
2400-60
0013
Circulator
Model
60.8
55.1
47.5
38.8
30.0
Flow
(GPM)
11.8
12.9
9.9
10.3
11.4
Boiler &
Piping
Head Loss
(ft.)
DT=25°F
1½
2
2
2
2
APX425C
APX525C
APX625C
APX725C
APX825C
Boiler
Model
2½
2
2
2
2
43.4
39.4
33.9
27.7
21.5
Supply
Near
& Return
Boiler
Connection Pipe Size Flow
(GPM)
(in.)
(in.)
6.4
7.1
5.5
5.8
6.4
Boiler &
Piping
Head Loss
(ft.)
DT=30°F
32.3
39.6
45.9
50.7
UPS43-44FC,
Spd. 2
UPS43-44FC,
Spd. 3
UPS43-100F,
Spd. 2
UPS43-100F,
Spd. 2
8.5
9.4
7.2
7.5
8.4
Boiler &
Flow
Piping
(GPM) Head Loss
(ft.)
25.1
Circulator
Model
UP26-64F
DT=35°F
UPS43-100F,
Spd. 3
UPS43-100F,
Spd. 3
UPS43-100F,
Spd. 2
UPS43-44F
UP26-99F
Circulator
Model
60.8
55.1
47.5
38.8
30.2
11.8
12.9
9.9
10.3
11.5
Boiler &
Flow
Piping
(GPM) Head Loss
(ft.)
59.4
68.9
76.0
UPS50-60F,
Spd. 3
UP50-60F,
Spd 3
48.5
UPS50-60F,
Spd. 2
UPS43-100F,
Spd. 2
37.7
UPS43-100F,
Spd. 2
76.0
68.9
59.4
48.5
37.5
Flow
(GPM)
Flow
(GPM)
2400-65
2400-65
2400-65
2400-60
2400-60
Circulator
Model
Circulator
Model
DT=25°F
Table 26: Recommended Grundfos Circulators for 50 Equivalent ft. Near Boiler Piping [Approximately 20 ft.
Straight Pipe, (4) 90° Elbows, and (2) Full Port Ball Valves]
1½
APX425C
Boiler
Model
Supply
Near Boiler
& Return
Pipe Size
Connection
(in.)
(in.)
Table 25: Recommended Taco Circulators for 50 ft. Equivalent ft. Near Boiler Piping [Approximately 20 ft.
Straight Pipe, (4) 90° Elbows, and (2) Full Port Ball Valves]
VI. Water Piping and Trim (continued)
17.6
19.1
14.7
15.2
16.9
Boiler &
Piping
Head Loss
(ft.)
DT=20°F
17.6
19.1
14.7
15.2
16.8
UPS50-80/2,
Spd. 3
UP50-80/2,
Spd 3
UPS40-80/2,
Spd. 3
UP50-60F,
Spd. 3
UPS43-100F,
Spd. 3
Circulator
Model
1935
1935
2400-70
2400-65
2400-70
Boiler &
Piping
Circulator
Head Loss
Model
(ft.)
DT=20°F
VI. Water Piping and Trim (continued)
Figure 26: Factory Supplied Piping and Trim Installation - APX525C, APX625C, APX725C and APX825C
C. Standard Installation Requirements.
Observe the following guidelines when making the
actual installation of the boiler piping:
1. Safety Relief Valve (Required) – The safety
relief valve is packaged loose with boiler and must
be installed in the location shown in Figure 25 or
26 “Factory Supplied Piping and Trim Installation”.
The safety relief valve must be installed with spindle
in vertical position. Installation of the safety relief
valve must comply with ASME Boiler and Pressure
Vessel Code, Section IV. The standard factory
shipped safety relief valve is set at 50 psi (340 kPa)
on APX425C and APX525C and 60 psi (410 kPa)
on APX625C, APX725C and APX825C. Optional
80 psi (550 kPa) and 100 psi (689 kPa) safety relief
valve kits are available. If the safety relief valve
is to be replaced, the replacement valve must have
a relief capacity equal or exceeding the minimum
relief valve capacity shown on the heat exchanger
ASME plate. Also, when replacing the safety relief
valve, verify the temperature and pressure gage
meets ASME requirements for the replacement
safety relief valve. Pipe the safety relief valve
discharge to a location where hot water or steam will
not create hazard or property damage if the valve
opens.
The end of the discharge pipe must terminate in an
unthreaded pipe. If the safety relief valve is not
piped to a drain, it must terminate at least 6 in. (150
mm) above the floor. Do not run safety relief valve
discharge piping through an area prone to freezing.
The termination of discharge piping must be in an
area where it will not become plugged by debris.
CAUTION
Burn Hazard. Safety relief valve discharge
piping must be piped such that the potential of
severe burns is eliminated. DO NOT pipe in any
area where freezing could occur. DO NOT install
any shut-off valves, plugs or caps. Consult local
codes for proper discharge piping arrangement.
2. Flow Switch (Required) – A flow switch is
required in lieu of manual reset low water cutoff
(LWCO) for forced circulation coil-type water
boilers to prevent overheating and heat exchanger
failure in accordance with requirements of ASME
Boiler and Pressure Vessel Code, Section IV, and
ANSI/ASME CSD-1 – latest edition, “Controls and
45
VI. Water Piping and Trim (continued)
Figure 27: Boiler Head Loss
Safety Devices for Automatically Fired Boilers”.
The flow switch is factory provided. Follow Section
VI, Paragraph A and Section VIII ‘Electrical’ of
these instructions to install and wire the flow switch.
3. Circulator (Required) – Usually at least two
circulators will be required to properly install an
Apex boiler. See Paragraph B above for information
on sizing the circulators.
8. Y-strainer (Recommended) – A Y-strainer
or equivalent strainer removes heating system
debris from hydronic systems and protects boiler
heat exchanger from fouling. Install the strainer
downstream of full port isolation valve at the inlet
side of the circulator for easy service.
4. Expansion Tank (Required) – If this boiler is
9. Flow Control Valve (Strongly
Recommended) – The flow control valve prevents
5. Fill Valve (Required) – Either manual
10. Isolation Valves (Strongly Recommended) –
replacing an existing boiler with no other changes
in the system, the old expansion tank can generally
be reused. If the expansion tank must be replaced,
consult the expansion tank manufacturer’s literature
for proper sizing.
(recommended) or automatic fill valve may be used.
However, if automatic refill is employed, a water
meter must be added to evaluate the makeup water
volume taken after initial fill and eliminate any
water leakage as early as possible.
6. Automatic Air Vent (Required) –At least one
automatic air vent is required. Manual vents will
usually be required in other parts of the system to
remove air during initial fill.
7. Manual Reset High Limit - Apex boilers have
factory provided UL 353 listed boiler control and
UL 1434 listed manual reset high limit. An optional
manual reset external high limit is available from
46
Thermal Solutions to meet local code requirements.
flow through the system unless the circulator is
operating. Flow control valves are used to prevent
gravity circulation or “ghost flows” in circulator
zone systems through zones that are not calling for
heat.
Isolation valves are useful when the boiler must be
drained, as they will eliminate having to drain and
refill the entire system.
11. Drain Valve (Required) – Drain valve is
packaged loose with boiler and must be installed
in the location shown in Figure 25 or 26 “Factory
Supplied Piping and Trim Installation”.
12. An optional LWCO with manual reset is
available from Thermal Solutions to meet local code
requirements.
VI. Water Piping and Trim (continued)
Table 27: Fitting and Valve Equivalent Length
(cont’d)
Table 27: Fitting and Valve Equivalent Length
Copper Fitting and Sweat Valve Equivalent Length (Ft)
Copper Pipe or Valve Size
Fitting or Valve
Description
1
1¼
1½
2
90° Elbow
45° Elbow
Tee (through flow)
Tee (Branch flow)
Diverter Tee (typical)
Gate Valve
Globe Valve
Angle Valve
Ball Valve (standard port)
Ball Valve (full port)
Swing Check Valve
Flow-Check Valve (typical)
Butterfly Valve
2.5
1.0
0.5
4.5
23.5
0.3
25.0
5.3
4.3
1.9
4.5
54.0
2.7
3.0
1.2
0.6
5.5
25.0
0.4
36.0
7.8
7.0
1.4
5.5
74.0
2.0
4.0
1.5
0.8
7.0
23.0
0.5
46.0
9.4
6.6
2.2
6.5
57.0
2.7
5.5
2.0
1.0
9.0
23.0
0.7
56.0
12.5
14.0
1.3
9.0
177.0
4.5
Threaded Fitting and Valve Equivalent Length (Ft)
Black Threaded Pipe or
Fitting or Valve
Valve Size
Description
1
1¼
1½
2
90° Elbow
Long Radius
Elbow (45° or 90°)
Tee (through flow)
Tee (Branch flow)
Close Return Bend
Gate Valve (full open)
Globe Valve (full open)
Angle Valve (full open)
Swing Check Valve
(full open)
Flow-Check Valve
(typical)
2.6
3.5
4.0
5.2
1.4
1.8
2.2
2.8
1.8
5.3
4.4
0.7
30.0
13.0
2.3
6.9
5.8
0.9
39.0
17.0
2.7
8.1
6.7
1.1
46.0
20.0
3.5
10.0
8.6
1.4
59.0
26.0
8.7
12.0
13.0
17.0
42.0
60.0
63.0
83.0
NOTE: Table 27 is provided as reference to assist in piping design and specifies equivalent length of typical piping
fittings and valves.
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.
• Before connecting the boiler, insure the system is free of impurities, grease, sediment, construction
dust, sand, copper dust, flux and any residual boiler water additives. Flush the system thoroughly
and repeatedly, if needed, with clear water mixed with concentrated rinse agent to remove these
contaminants completely.
• Iron oxide (red oxide sludge Fe2O3) is produced during oxygenation. To minimize any oxygen pres-
ence in the system, the system must be air free and leak tight. Do not connect the boiler to radiant
tubing without an oxygen barrier. Using automatic water refill is not recommended, however, if such
refill is employed, a water meter must be added to evaluate the makeup water volume taken after initial fill and eliminate any water leakage as early as possible.
• Maintain the water pressure in the boiler at a minimum of 14.50 psi (100 kPa).
• The boiler water pH must be within 7.5 < pH < 9.5. If the system contains any aluminum components,
pH must be less than 8.5.
• Black oxide sludge (magnetite Fe O ) forms as the result of continuous electrolytic corrosion in any
3 4
system not protected by an inhibitor.
• Scale deposit is made up of lime scale contained in most distributed water and settles over the warm-
est surfaces of boiler heat exchanger causing subsequent overheating and eventual failure. Water
hardness must be maintained within 3 to 9 grain/gal range.
• Refer to Section XI “Service and Maintenance” for recommended heating system water treatment products
(corrosion/scale inhibitors, cleaners etc) and their suppliers.
47
48
VI. Water Piping and Trim (continued)
Figure 28: Near Boiler Piping - Heating Only
49
Figure 29: Near Boiler Piping - Heating Plus Indirect Water Heater
VI. Water Piping and Trim (continued)
VI. Water Piping and Trim (continued)
D. Special Situation Piping Installation
Requirements
Observe the following guidelines when making the
actual installation of the boiler piping for special
situations:
1. Systems containing high level of dissolved
oxygen – Many hydronic systems contain enough
dissolved oxygen to cause severe corrosion damage
to Apex boiler heat exchanger. Some examples
include but not limited to:
• Radiant systems employing tubing without
oxygen barrier
• Systems with routine additions of fresh water
• Systems open to atmosphere
If the boiler is used in such a system, it must be
separated from oxygenated water being heated
with a heat exchanger as shown in Figures 30 and
31. Consult the heat exchanger manufacturer for
proper heat exchanger sizing as well as flow and
temperature requirements. All components on the
oxygenated side of the heat exchanger, such as the
pump and expansion tank, must be designed for use
in oxygenated water.
2. Piping with a Chiller - If the boiler is used in
conjunction with a chiller, pipe the boiler and chiller
in parallel. Use isolation valves to prevent chilled
water from entering the boiler.
3. Boiler Piping with Air Handlers - Where the
boiler is connected to air handlers through which
refrigerated air passes, use flow control valves in the
boiler piping or other automatic means to prevent
gravity circulation during the cooling cycle.
Table 28: Multiple Boiler Water Manifold Sizing
Boiler Model
APX425C
APX525C
APX625C
APX725C
APX825C
Number of Units
3
4
5
6
7
8
Recommended Minimum Common
Water Manifold Size (NPT)
2½”
3”
3”
4”
5”
5”
5”
3”
4”
4”
5”
5”
6”
6”
3”
4”
5”
5”
6”
6”
6”
4”
4”
5”
6”
6”
8”
8”
4”
5”
5”
6”
6”
8”
8”
2
Figure 30: Isolation of the Boiler From Oxygenated Water with A Plate Heat Exchanger
(IWH Piped as Part of Boiler Piping)
50
VI. Water Piping and Trim (continued)
Figure 31: Isolation of the Boiler From Oxygenated Water with A Plate Heat Exchanger
(IWH Piped Off System Header)
E. Multiple Boiler Water Piping
1. See Figure 34 for example multiple boiler
piping.
2. Install one header sensor in system piping
downstream of the boiler supply connection. See
Figure 34 for header sensor location and Figures 32
and 33 for installation detail. Wire header sensor
to Sequencer Master boiler. See also Section VIII
“Electrical” and Section X “Operation”.
Figure 32: Recommended Direct Immersion
Header Sensor or DHW Sensor Installation Detail
3. For installations where indirect domestic hot
water heater is combined with space heating,
the Alliance SL™ model must be piped as a
separate heating zone off the system header. The
circulator must be sized based on the Alliance SL™
model coil flow and combined coil pressure drop
and the zone piping total equivalent length. Refer
to Alliance SL™ Indirect Water Heater literature for
specific model coil flow and pressure drop. Refer to
Figure 34.
Figure 33: Alternate “Immersion” Type Header
Sensor or DHW Sensor Installation Detail
51
52
Figure 34: Multiple Boiler Water Piping w/Domestic Hot Water Heater (Page 1 of 2)
Installing a low water cutoff in the system piping
of multiple boilers is strongly recommended and
may be required by local codes.
NOTICE
VI. Water Piping and Trim (continued)
53
Figure 34, continued: Multiple Boiler Water Piping w/Domestic Hot Water Heater (Page 2 of 2)
Installing a low water cutoff in the system piping
of multiple boilers is strongly recommended and
may be required by local codes.
NOTICE
VI. Water Piping and Trim (continued)
VII. Gas Piping
1. Allowable pressure drop from point of
delivery to boiler. Maximum allowable system
pressure is ½ psig (3.4 kPa). Actual point of delivery
pressure may be less; contact gas supplier for
additional information. Minimum gas valve inlet
pressure is printed on the rating label located in the
boiler’s vestibule compartment.
WARNING
Explosion Hazard. Failure to properly pipe gas
supply to boiler may result in improper operation
and damage to the boiler or structure. Always
assure gas piping is absolutely leak free and of
the proper size and type for the connected load.
An additional gas pressure regulator may be
needed. Consult gas supplier.
2. Maximum gas demand. Refer to the boiler’s
input as printed on its rating label. Also consider
existing and expected future gas utilization
equipment (i.e. water heater, cooking equipment).
3. Length of piping and number of fittings.
NOTICE
Refer to Tables 29 (natural gas) or 30 (LP gas) for
maximum capacity of Schedule 40 pipe. Table 31
lists equivalent pipe length for standard fittings.
Size corrugated stainless steel tubing (CSST)
to ensure proper capacity and minimize flow
restrictions.
4. Specific gravity of gas. Gas piping systems for
gas with a specific gravity of 0.60 can be sized
directly from Table 29 and gas with a specific
gravity of 1.5 can be sized from Table 30, unless
authority having jurisdiction specifies a gravity
factor be applied. For other specific gravity, apply
gravity factor from Table 32. If exact specific
gravity is not shown choose next higher value.
A. Size gas piping. Design system to provide
adequate gas supply to boiler. Consider
these factors:
Table 29: Maximum Capacity of Schedule 40 Black Pipe in CFH* (Natural Gas) For Gas Pressures
of 1/2 psi (3.4 kPa) or Less
Inlet Pressure 14.0 in wc (3.4 kPa)or less; 0.3 in wc (0.07 kPa) Pressure Drop
Nominal Pipe
Size, In.
Inside
Diameter, In.
Length of Pipe, Ft.
10
20
30
40
50
60
70
80
90
100
½
0.622
131
90
72
62
55
50
46
42
40
38
¾
0.824
273
188
151
129
114
104
95
89
83
79
1
1.049
514
353
284
243
215
195
179
167
157
148
1¼
1.380
1060
726
583
499
442
400
368
343
322
304
1½
1.610
1580
1090
873
747
662
600
552
514
482
455
2
2.067
3050
2090
1680
1440
1280
1160
1060
989
928
877
2½
2.469
4860
3340
2680
2290
2030
1840
1690
1580
1480
1400
3
3.068
8580
5900
4740
4050
3590
3260
3000
2790
2610
2470
Inlet Pressure 14.0 in wc (3.4 kPa)or less; 0.5 in wc (0.12 kPa) Pressure Drop
Nominal Pipe
Size, In.
Inside
Diameter, In.
Length of Pipe, Ft.
10
20
30
40
50
60
70
80
90
100
½
0.622
172
118
95
81
72
65
60
56
52
50
¾
0.824
360
247
199
170
151
137
126
117
110
104
1
1.049
678
466
374
320
284
257
237
220
207
195
1¼
1.380
1390
957
768
657
583
528
486
452
424
400
1½
1.610
2090
1430
1150
985
873
791
728
677
635
600
2
2.067
4020
2760
2220
1900
1680
1520
1400
1300
1220
1160
2½
2.469
6400
4400
3530
3020
2680
2430
2230
2080
1950
1840
3
3.068
11300
7780
6250
5350
4740
4290
3950
3674
3450
3260
* 1 CFH of Natural Gas is approximately equal to 1 MBH; contact your gas supplier for the actual heating value of your
gas.
54
VII. Gas Piping (continued)
Table 32: Specific Gravity Correction Factors
For materials or conditions other than those listed
above, refer to National Fuel Gas Code, ANSI Z223.1/
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.
Specific
Gravity
Correction
Factor
Specific
Gravity
Correction
Factor
0.60
1.00
0.90
0.82
0.65
0.70
0.75
0.80
0.85
0.96
0.93
0.90
0.87
0.81
1.00
1.10
1.20
1.30
1.40
0.78
0.74
0.71
0.68
0.66
Table 30: Maximum Capacity of Schedule 40 Black Pipe in CFH* (LP Gas) For Gas Pressures
of 1/2 psi (3.4 kPa) or Less
Inlet Pressure 11.0 in wc (2.7 kPa); 0.3 in wc (0.07 kPa) Pressure Drop
Nominal Pipe
Size, In.
Inside
Diameter, In.
Length of Pipe, Ft.
10
20
30
40
50
60
70
80
90
100
½
0.622
88
60
48
41
37
33
31
29
27
25
¾
0.824
184
126
101
87
77
70
64
60
56
53
1
1.049
346
238
191
163
145
131
121
112
105
100
1¼
1.380
710
488
392
336
297
269
248
231
216
204
1½
1.610
1064
732
588
503
446
404
371
346
324
306
2
2.067
2050
1409
1131
968
858
778
715
666
624
590
2½
2.469
3267
2246
1803
1543
1368
1239
1140
1061
995
940
3
3.068
5776
3970
3188
2729
2418
2191
2016
1875
1760
1662
80
90
100
Inlet Pressure 11.0 in wc (2.7 kPa); 0.5 in wc (0.12 kPa) Pressure Drop
Nominal Pipe
Size, In.
Inside
Diameter, In.
Length of Pipe, Ft.
10
20
30
40
50
60
70
½
0.622
116
80
64
55
48
44
40
38
35
33
¾
0.824
242
166
134
114
101
92
85
79
74
70
1
1.049
456
314
252
215
191
173
159
148
139
131
1¼
1.380
937
644
517
442
392
355
327
304
285
269
1½
1.610
1403
964
775
663
588
532
490
456
427
404
2
2.067
2703
1858
1492
1277
1131
1025
943
877
823
778
2½
2.469
4308
2961
2377
2035
1803
1634
1503
1399
1312
1239
3
3.068
7615
5234
4203
3597
3188
2889
2658
2472
2320
2191
* 1 CFH of LP Gas is approximately equal to 2.5 MBH; contact your gas supplier for the actual heating value of your gas.
Table 31: Equivalent Lengths of Standard Pipe Fittings & Valves (ft)
Nominal
Pipe Size,
Inc.
Inside
Diameter,
In.
Valves (Screwed) - Fully Open
Gate
Globe
Angle
Swing
Check
Screwed Fittings
45°
Elbow
90°
Elbow
180 Close
Return Bend
90 Tee Flow
Through
Run
90 Tee, Flow
Through
Branch
½
0.622
0.4
17.3
8.7
4.3
0.7
1.6
3.5
1.6
3.1
¾
0.824
0.5
22.9
11.4
5.7
1.0
2.1
4.6
2.1
4.1
1
1.049
0.6
29.1
14.6
7.3
1.2
2.6
5.8
2.6
5.2
1¼
1.38
0.8
38.3
19.1
9.6
1.6
3.5
7.7
3.5
6.9
1½
1.61
0.9
44.7
22.4
11.2
1.9
4.0
9.0
4.0
8.0
2
2.067
1.2
57.4
28.7
14.4
2.4
5.2
11.5
5.2
10.3
2½
2.469
1.4
68.5
34.3
17.1
2.9
6.2
13.7
6.2
12.3
3
3.068
1.8
85.2
42.6
21.3
3.6
7.7
17.1
7.7
15.3
55
VII. Gas Piping (continued)
WARNING
Explosion Hazard. Failure to use proper
thread compounds on all gas connectors
may result in leaks of flammable gas.
Gas supply to boiler and system must be
absolutely shut off prior to installing or
servicing boiler gas piping.
B. Connect boiler gas valve to gas supply
system.
1. Use methods and materials in accordance
with local plumbing codes and requirements of gas
supplier. In absence of such requirements, follow
National Fuel Gas Code, ANSI Z223.1/NFPA 54
and/or Natural Gas and Propane Installation Code,
CAN/CSA B149.1.
2. Use thread (joint) compounds (pipe dope)
resistant to action of liquefied petroleum gas.
3. Apex boilers have factory supplied
miscellaneous parts cartons, which include gaspiping components to connect boiler gas valve(s) to
gas supply system. Install these components prior
to connecting boiler to gas supply system piping as
follows:
Boiler
Model
Miscellaneous
Parts Carton
APX425C
APX525C
APX625C
APX725C
APX825C
106315-01
106316-01
106317-01
Models APX425C and APX525C
a. Locate and remove the ¾ in. NPT x 6 in. long
black nipple and ¾ in. NPT external gas shutoff
valve (required).
b. Insert nipple though grommet in left side panel.
Apply pipe dope and thread nipple into gas valve
(APX425C) or gas inlet tee (APX525C).
c. Mount the ¾ in. NPT external gas shutoff valve
onto the nipple threaded end outside of the jacket
left side panel.
d. Install sediment trap, ground-joint union and
manual shut-off valve upstream of mounted
factory supplied manual shut-off valve. See
Figure 35 “ Recommended Gas Piping ”.
56
Figure 35: Recommended Gas Piping
Models APX625C, APX725C and APX825C
e. Locate and remove 1 in. NPT external gas
shutoff valve (required).
f. Insert nipple through grommet in left side panel.
Apply pipe dope and thread nipple into gas inlet
tee or cross.
g. Mount the 1 in. NPT external gas shutoff valve
onto the nipple threaded end outside of the jacket
left side panel.
h. Install sediment trap, ground-joint union and
manual shut-off valve upstream of mounted
factory supplied manual shut-off valve. See
Figure 35 “ Recommended Gas Piping”.
4. All above ground gas piping upstream
from manual shut-off valve must be electrically
continuous and bonded to a grounding electrode. Do
not use gas piping as grounding electrode. Refer to
National Electrical Code, NFPA 70 and/or Canadian
Electrical Code Part 1, CSA C22.1, Electrical Code.
Table 33: Min./Max. Inlet Gas Pressure Ratings
Boiler
Model
Natural/LP
Gas Max,
in. wc (kPa)
Natural Gas
Min,
in. wc (kPa)
LP Gas
Min,
in. wc (kPa)
14.0
(3.49)
4.0
(1.00)
8.0
(1.99)
APX425C
APX525C
APX625C
APX725C
APX825C
VII. Gas Piping (continued)
C. Pressure test. See Table 33 for Apex Min./Max.
Pressure Ratings. The boiler and its gas connection
must be leak tested before placing boiler in operation.
1. Protect boiler gas control valve. For all testing
over ½ psig (3.4 kPa), boiler and its individual
shutoff valve must be disconnected from gas supply
piping. For testing at ½ psig (3.4 kPa) or less, isolate
boiler from gas supply piping by closing boiler’s
individual manual shutoff valve.
2. Locate leaks using approved combustible gas noncorrosive leak detector solution.
2. The low gas pressure switch must be reset after
the boiler is piped to the gas supply and before it is
fired.
3. For the low and high gas pressure switches
proper operation, the boiler inlet gas pressure must
be within the range shown in Table 33.
4. The gas pressure can be measured at the gas
valve inlet pressure port. Refer to Figure 36 “Gas
Inlet Pressure Tap and Pressure Switch Location “.
5. If either pressure switch is tripped, it must be
manually reset before the boiler can be restarted.
DANGER
Explosion Hazard. Do not use matches, candles,
open flames or other ignition source to check for
leaks.
D. Apex Models APX525C, APX625C,
APX725C, APX825C (if equipped with optional
low and high gas pressure switches)
1. Verify low and high gas pressure switch
settings are within the range shown in kit
instructions. The switches are preset for natural gas.
For LP gas, the low gas pressure switch setting must
be adjusted.
Figure 36: Gas Inlet Pressure Tap and Pressure Switch Location
57
VII. Gas Piping (continued)
E. Gas Piping for Multiple Boiler Installation
1.Individual module (boiler) gas pipe sizing
specific details - see Paragraph A.
2. Individual module (boiler) recommended gas
piping detail - see Figure 35.
3. An additional gas pressure regulator(s) may need
to be installed to properly regulate inlet gas pressure
at the smallest individual module (boiler).
58
CAUTION
If gas pressure in the building is above ½ psig
(3.4 kPa), an additional gas pressure regulator
is required. Using one additional regulator
for multiple boilers may result in unsafe boiler
operation. The additional regulator must be able
to properly regulate gas pressure at the input
of the smallest boiler. If the regulator cannot
do this, two or more additional regulators are
required. Consult regulator manufacturer and/or
local gas supplier for instructions and equipment
ratings.
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. Failure to properly wire electrical connections to the boiler may result in
serious physical harm.
Electrical power may be from more than one source. Make sure all power is off before attempting any
electrical work.
Each boiler must be protected with a properly sized over-current device.
Never jump out or make inoperative any safety or operating controls.
The wiring diagrams contained in this manual are for reference purposes only. Each boiler is shipped
with a wiring diagram attached to the front door. Refer to this diagram and the wiring diagram of any
controls used with the boiler. Read, understand and follow all wiring instructions supplied with the
controls.
NOTICE
All wire, wire nuts, controls etc. are installer supplied unless otherwise noted.
A.General. Install wiring and electrically ground boiler
in accordance with authority having jurisdiction or, in
the absence of such requirements, follow the National
Electrical Code, NFPA 70, and/or Canadian Electrical
Code Part 1, CSA C22.1 Electrical Code. Provide over
current protection not greater than 15A.
B. A separate electrical circuit must be run
from the main electrical service with an over-current
device/disconnect in the circuit. A service switch is
recommended and may be required by some local
jurisdictions. Install the service switch in the line
voltage “Hot” leg of the power supply. Locate the
service switch such that the boiler can be shut-off
without exposing personnel to danger in the event of an
emergency.
C. Power Requirements
Nominal boiler current draw is provided in Table
34. These values are for planning purposes only
and represent only the boiler’s power consumption.
To obtain total system power consumption add any
selected circulator and component current draws.
Table 34: Boiler Current Draw
Model Number
Nominal Current
(amps)
APX425C
<7
APX525C
<6
APX625C
<8
APX725C
<8
APX825C
<8
D. Boiler wiring. Refer to Figures 40 and 41.
1. Connect to field wiring inside the junction box,
located on the upper left side of the boiler as shown
in Figure 37. Inside the junction box are two printed
circuit boards (PCB’s), 120 VAC Connections on the
left and Low Voltage Connections on the right.
2. 120VAC connections (line voltage) are located
on left PCB and are shown in Figure 38. Do not
exceed 5.6A total pump current draw (system +
DHW + boiler pumps). One 6.3A slow-blow pump
fuse and spare are provided.
59
VIII. Electrical (continued)
Figure 37: PCB Locations for Field Wiring
Figure 38: 120 VAC Field Wiring
60
VIII. Electrical (continued)
3. 24VAC low voltage connections are located on
NOTICE
left side of right PCB and are shown in Figure 39.
One 24V fuse and spare are provided. APX425C
and APX525C use 1.6A slow-blow fuse. APX625C,
APX725C and APX825C use 2.0A fast-acting fuse.
When making low voltage connections, make
sure that no external power source is present
in the thermostat or limit circuits. If such a
power source is present, it could destroy the
boiler’s microprocessor control. One example
of an external power source that could be
inadvertently connected to the low voltage
connections is a transformer in old thermostat
wiring.
4. 5VDC low voltage connections are located on
right side of right PCB and are shown in Figure 38.
5.If the outdoor sensor is connected, the boiler
will adjust the target space heating set point supply
water temperature downwards as the outdoor air
temperature increases. If used, this sensor should
be located on the outside of the structure in an area
where it will sense the average air temperature
around the house. Avoid placing this sensor in areas
where it may be covered with ice or snow. Locations
where the sensor will pick up direct radiation from
the sun should also be avoided. Avoid placing the
sensor near potential sources of electrical noise
such as transformers, power lines, and fluorescent
lighting. Wire the sensor to the boiler using 22
gauge or larger wire. As with the sensor, the sensor
wiring should be routed away from sources of
electrical noise. Where it is impossible to avoid such
noise sources, wire the sensor using a 2 conductor,
UL Type CM, AWM Style 2092, 300 Volt 60°C
shielded cable. Connect one end of the shielding on
this cable to ground.
E. Flow Switch Wiring
Apex boilers require a flow switch to prevent boiler
overheating. See Section VI “Water Piping and Trim”, and
flow switch instruction sheet for piping details. The flow
switch and flow switch wire harness are factory provided.
1. Wire flow switch harness to boiler. Connect
Molex on harness to boiler low voltage connector
P11, labeled “Flow Switch”.
2. Wire flow switch harness to flow switch. Connect fork terminals on harness to flow switch
NO (normally open) and COM (common) terminal
screws.
SIZE 399-525: 1.6A SLOW BLOW
SIZE 600-825: 2.0A FAST ACTING
5mm X 20mm FUSE
OPTIONAL
OUTDOOR
SENSOR
SPACE HEATING
THERMOSTAT
OPTIONAL
DOMESTIC HOT WATER
THERMOSTAT (IF USED)
OPTIONAL AUTO
RESET EXTERNAL
LIMIT(S)
OR
OPTIONAL
HEADER SENSOR
DAMPER PROVING
SWITCH (IF USING
ROOM AIR)
(+)
OPTIONAL MANUAL RESET
EXTERNAL LIMIT(S)
OPTIONAL
DOMESTIC HOT
WATER SENSOR
(-)
ALARM CONTACTS
OPTIONAL ENVIRACOM
THERMOSTAT OR
ZONE PANEL
OR
OR
FLOW
SWITCH
OPTIONAL
ENERGY
MANAGEMENT
SYSTEM
OR
OPTIONAL
MULTIPLE BOILER
COMMUNICATION
OPTIONAL
24V LWCO
Figure 39: Low Voltage Field Wiring
61
VIII. Electrical (continued)
Figure 40: Ladder Diagram
62
VIII. Electrical (continued)
2
Figure 41: Wiring Connections Diagram
63
VIII. Electrical (continued)
Figure 42: 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
64
65
Figure 43: Modified Wiring For DHW Priority When Using Low Flow Circulator Piped Off System Header Heating (with Central Heating Zone Valves) Plus Alternately Piped Indirect Water Heater
VIII. Electrical (continued)
66
VIII. Electrical (continued)
Figure 44: Multiple Boiler Wiring Diagram
Internal Multiple Boiler Control Sequencer
(Two Boilers Shown, Typical Connections for up to Eight Boilers)
67
Tekmar 265 Based Control System (or equal)
Sequence of Operation
Figure 45: Multiple Boiler Wiring Diagram w/Tekmar 265 Control
The Tekmar 265 Control (or equal) can control up to three (3) boilers and an Indirect Water Heater. When a call for heat is received by the Tekmar 265 Control, the control
will fire either one or more boilers in either parallel or sequential firing mode to establish a required reset water temperature in the system supply main based on outdoor
temperature. The boilers will modulate based on an Analog communication signal established between the Tekmar 265 Control and each boiler’s control. The boiler(s) and
system supply water temperature will be reset together to maintain the input that is needed to the system. When a call for Indirect Hot Water is generated to the Tekmar 265,
the control will de-energize the zone pump control (ZC terminal), energize the Indirect pump and modulate the boiler firing to establish a setpoint temperature in the main for the
Indirect Heater using Priority. The Tekmar 265 also controls each boiler’s pump and a post purge of leftover temperature in the boilers will occur at the end of the call for Indirect
Hot Water.
VIII. Electrical (continued)
68
Tekmar 264 Based Control System (or equal)
Sequence of Operation
Figure 46: Multiple Boiler Wiring Diagram w/Tekmar 264 Control
The Tekmar 264 Control (or equal) can control up to four (4) boilers and an Indirect Water Heater by utilizing stage firing. When a call for heat is received by the Tekmar 264
Control, the control will fire either one or more boilers in sequential firing mode to establish a required reset water temperature in the system supply main based on outdoor
temperature. The boilers will modulate on their own based on each boiler’s control and will target a setpoint temperature to supply enough input to the system main to satisfy
the desired reset water temperature in the main established by the Tekmar 264 Control. When a call for Indirect Hot Water is generated to the Tekmar 264, the control will deenergize the zone pump control (ZC terminal), energize the Indirect pump and sequentially fire the boilers to establish a setpoint temperature in the main for the Indirect Heater
using Priority. The Tekmar 264 Control will disable the stage firing and post purge the Indirect Pump to reduce the temperature in the Supply Main near the end of the Indirect
Mode to a point where it will need to be when it changes back to Space Heating Mode. The Tekmar 264 Control also has the ability to rotate the lead-lag firing of the boilers to
establish equal operating time for each boiler stage.
VIII. Electrical (continued)
VIII. Electrical (continued)
F. Multiple Boiler Wiring
1. Install over-current protection in accordance
with authority having jurisdiction or, in the absence
of such requirements, follow the National Electric
Code, NFPA 70, and/or Canadian Electrical Code
Part 1, CSA C22.1. Do not provide over-current
protection greater than 15 amperes. If it becomes
necessary to provide greater amperes (because of
the number of boilers provided) use separate circuits
and over-current protection for additional boilers.
2. Required Equipment and Setup
a. Header Sensor (P/N 101935-01 or 103104-01)
A header sensor must be installed and wired to
the Sequencer Master boiler. The header sensor
is installed on the common system piping and
provides blended temperature information to
the Sequence Master. Refer to Figure 34 for
installation location and Figure 32 or 33 for
installation detail.
b. Ethernet Cables
Ethernet cables are used to connect the boiler
network together. These are standard “straight
through” cables that can be purchased at
electrical distributors.
Alternately, the network can be wired together by
simply wiring Modbus Boiler-to-Boiler terminals
A, B, and C between each boiler. Refer to
Figures 40, 41 and 44 for wiring location.
G. External Multiple Boiler Control System
As an alternate to the control internal sequencer, the 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. The Tekmar Model 264 and Model
265 based control wiring diagrams (Figures 45 and 46) are
provided as examples of typical multiple boiler control
systems.
69
IX. System Start-up
WARNING
Explosion Hazard. Asphyxiation Hazard.
Electrical Shock Hazard. Start-up of this boiler
should be undertaken only by trained and skilled
personnel from a qualified service agency.
Follow these instructions exactly. Improper
installation adjustment, service or maintenance
can cause property damage, personal injury or
loss of life.
E. Confirm that the boiler and system have no
water leaks.
NOTICE
A. Verify that the venting, water piping, gas
piping and electrical system are installed
properly. Refer to installation instructions contained
If it is required to perform a long term pressure
test of the hydronic system, the boiler should
first be isolated to avoid a pressure loss due to
the escape of air trapped in the boiler.
To perform a long term pressure test including
the boiler, ALL trapped air must first be removed
from the boiler.
A loss of pressure during such a test, with no
visible water leakage, is an indication that the
boiler contained trapped air.
B. Confirm all electrical, water and gas
supplies are turned off at the source and that
F. Check all gas piping for leaks and purge piping
in this manual.
vent is clear of obstructions.
C. Confirm that all manual shut-off gas valves
between the boiler and gas source are closed.
sections that are filled with air. Refer to National
Fuel Gas Code, ANSI Z223.1/NFPA 54 or, in Canada,
Natural Gas and Propane Installation Code, CAN/CSA
B149.1.
D. If not already done, flush the system to
remove sediment, flux and traces of boiler additives.
This must be done with the boiler isolated from the
system. Fill entire heating system with water meeting
the following requirements:
NOTICE
pH between 7.5 and 9.5.
If system contains aluminum components, pH
must be less than 8.5
Chlorides< 50 ppm
Total Dissolved Solids - less than 2500 PPM
Hardness - 3 to 9 grains/gallon.
Pressurize the system to at least 14.5 psi (100 kPa).
Purge air from the system. A manual air vent is located
on the right side of the heat exchanger inside the
cabinet.
WARNING
Burn Hazard. The maximum operating pressure
of this boiler is 30 psig (210 kPa), 50 psig
(340 kPa), 60 psig (410 kPa), 80 psig (550 kPa)
or 100 psig (689 kPa) depending on the model
and safety relief valve option selected. Never
exceed the maximum allowable working pressure
on the heat exchanger ASME plate.
70
DANGER
Explosion Hazard. Do not use matches, candles,
open flames or other ignition source to check for
leaks.
Make sure that the area around the boiler is clear
and free from combustible materials, gasoline
and other flammable vapors and liquids.
G. Confirm vent system is complete and free of
obstructions before attempting to fire boiler.
H. Inspect all wiring for loose, uninsulated, or
miswired connections.
I. If boiler is to be converted to LP gas
(propane), convert as described in Part T of this
section of the manual. Only models APX425C and
APX525C can be converted to LP gas. Models
APX625C, APX725C and APX825C are factory built
for LP gas and cannot be converted.
J. If boiler is operating at elevations above
2000 ft, see Appendix A for setup instructions.
K. Start the boiler using operating instructions
in Figure 47. After the boiler is powered up with a call
for heat, the boiler should go through the sequence of
operation shown in Table 49.
IX. System Start-up (continued)
Figure 47: Operating Instructions
71
IX. System Start-up (continued)
L. Upon initial start-up, the gas train will
be filled with air. Even if the gas line has been
completely purged of air, it may take several tries for
ignition before a flame is established. If more than
2 tries for ignition are needed, it will be necessary to
press the reset button to restart the boiler. Once a flame
has been established for the first time, subsequent calls
for burner operation should result in a flame on the first
try.
M.Check Burner Flame
Inspect the flame visible through the window. On high
fire the flame should be stable and mostly blue (Figure
48). No yellow tipping should be present; however,
intermittent flecks of yellow and orange in the flame are
normal.
N. Check Gas Inlet Pressure
Check the inlet pressure and adjust if necessary. Verify
that the inlet pressure is between the upper and lower
limits shown on the rating plate with all gas appliances
on and off.
WARNING
Asphyxiation Hazard. The outlet pressure for
the gas valve has been factory set and requires
no field adjustment. This setting is satisfactory
for both natural gas and propane. Attempting to
adjust the outlet pressure may result in damage
to the gas valve and cause property damage,
personal injury or loss of life.
O. Perform Combustion Test
WARNING
Asphyxiation Hazard. Each Apex Series boiler
is tested at the factory and adjustments to the
air fuel mixture are normally not necessary.
Improper gas valve or mixture adjustments could
result in property damage, personal injury or
loss of life.
WARNING
Any gas valve adjustments (throttle and/
or offset) specified herein and subsequent
combustion data (%O2, %CO2, CO air free ppm)
collection must be performed using a calibrated
combustion analyzer.
Failure to use combustion analyzer could result
in property damage, personal injury or loss of
life.
1. Use a combustion analyzer to sample boiler
flue gas and measure O2 (or CO2) and CO air
free. Boilers are equipped with a screw cap in the
vent connector. Be sure to replace this cap when
combustion testing complete.
2. Verify O2 (or CO2) and CO air free are
within limits specified in Table 35 for natural gas
or Table 36 for LP gas (propane). Note: Tables 35
and 36 are for sea level only. For altitudes above
2000 ft, see Appendix A.
a. Lock boiler in high fire and allow fan speed and
combustion analyzer reading to stabilize before
taking combustion readings. To lock boiler in
high fire, select MAIN MENU >> OPERATION.
Select lock symbol, type password “86” and
select ENTER. From the Operation screen,
select Automatic / Manual Firing Rate Control
>>Manual Modulation. Go back to Operation
screen. Then select High Low >> High.
Table 35: Natural Gas Typical Combustion
Readings (Sea level Only)
Boiler
Model
APX425C
APX525C
APX625C
APX725C
APX825C
CO2 %
O2 %
CO air free
(PPM)
8.6 - 9.2
8.7 - 9.2
8.6 - 9.2
8.2 - 8.9
8.2 - 9.1
4.7 - 5.8
4.7 - 5.6
4.7 - 5.6
5.2 - 6.5
4.9 - 6.5
Less than
200 PPM
Table 36: LP Gas (Propane) Typical Combustion
Readings (Sea Level Only)
Boiler
Model
APX425C
APX525C
APX625C
APX725C
APX825C
72
CO2 %
O2 %
CO air free
(PPM)
9.4 - 10.2
9.8 - 10.2
9.4 - 10.2
9.7 - 10.0
9.4 - 10.2
5.4 - 6.6
5.4 - 6.0
5.4 - 6.6
5.7 - 6.2
5.4 - 6.6
Less than
200 PPM
IX. System Start-up (continued)
Figure 48: Burner Flame
e. If low fire O2 is too low (CO2 is too high),
increase O2 (decrease CO2) by turning offset
WARNING
screw counterclockwise in less than 1/8 turn
increments and checking the O2 (or CO2)
Make sure that all adjustments at high fire are
after each adjustment. If boiler is equipped
made with the throttle, not offset screw (see
with 2 gas valves, offset screw adjustments
Figure 49). The offset screw has been factory set
must be done to both gas valves equally and
using precision instruments and must never be
simultaneously. Refer to Figure 49 for location
adjusted in the field unnecessarily.
of offset screw. Verify CO air free is less than
Attempting to adjust the offset screw
200 ppm.
unnecessary could result in damage to the gas
valve and may cause property damage, personal
f. If low fire O2 is too high (CO2 is too low),
injury or loss of life.
decrease O2 (increase CO2) by turning offset
screw clockwise in less than 1/8 turn increments
b. If high fire O2 is too low (CO2 is too high),
and checking the O2 (or CO2) after each
increase O2 (decrease CO2) by turning the throttle
adjustment. If boiler is equipped with 2 gas
screw clockwise in 1/4 turn increments and
valves, offset screw adjustments must be done
checking the O2 (or CO2) after each adjustment.
to both gas valves equally and simultaneously.
If boiler is equipped with 2 gas valves, throttle
Refer to Figure 49 for location of offset screw.
screw adjustments must be done to both gas
Verify CO air free is less than 200 ppm.
valves equally and simultaneously. Refer to
Figure 49 for location of throttle screw. Verify
CO air free is less than 200 ppm.
c. If high fire O2 is too high (CO2 is too low),
decrease O2 (increase CO2) by turning the
throttle screw counter-clockwise in 1/4 turn
increments and checking the O2 (or CO2)
after each adjustment. If boiler is equipped
with 2 gas valves, throttle screw adjustments
must be done to both gas valves equally and
simultaneously. Refer to Figure 49 for location
of throttle screw. Verify CO air free is less than
200 ppm.
d. Lock boiler in low fire and allow fan speed and
combustion analyzer reading to stabilize before
taking combustion readings. To lock boiler in
low fire, select High Low >> Low.
Figure 49: Gas Valve Detail
3. Remove analyzer probe and replace cap on
boiler vent connector.
4. Return boiler to Automatic Mode. From
Operation screen, select Automatic / Manual Firing
Rate Control >> Automatic Modulation. Select
HOME to return boiler to Home Screen.
P. Test Safety Limits Controls
WARNING
Asphyxiation Hazard. Offset screw is adjusted
at the factory to the specification. DO NOT
touch the offset screw if measured low fire O2
(or CO2) is within limits specified in Table 35 or
36.
1. Test the ignition system safety shut-off by
disconnecting the flame sensor connector (black
plug with orange wire) from the flame ionization
electrode. See Figure 40. The boiler must shut
down and must not start with the flame sensor
disconnected.
73
IX. System Start-up (continued)
2. Test the flow switch by disabling the primary
loop circulator. The boiler must not start if flow is
not present.
3. Test any other external limits or other controls
in accordance with the manufacturer’s instructions.
Q. Check Thermostat Operation
Verify that the boiler starts and stops in response to
calls for heat from the heating thermostat and indirect
water heater thermostat. Make sure that the appropriate
circulators also start and stop in response to the
thermostats.
R. Adjust Supply Water Temperature
As shipped, the heating set point supply temperature
is set to 180°F (82.2°C) and, indirect water heater set
point supply temperature is set to 170°F (76.7°C). If
necessary, adjust these to the appropriate settings for
the type of system to which this boiler is connected.
See Section X “Operation” (parameter table on page
94) of this manual for information on how to adjust
supply setpoint.
S. Adjust Thermostats
Adjust the heating and indirect water heater thermostats
to their final set points.
T. Field Conversion From Natural Gas to LP
Gas (Propane)
Apex models APX425C and APX525C are factory
shipped as natural gas builds and can be field converted
to LP gas. Follow steps below for field conversion from
natural gas to LP Gas.
Models APX625C, APX725C and APX825C are
factory shipped as either natural gas build or LP
gas build. Field conversions of models APX625C,
APX725C and APX825C are not permitted.
1.Conversion of Apex models APX425C and
APX525C from one fuel to another is accomplished
using the throttle screw on the gas valve. Figure 49
“Gas Valve Detail” shows the location of the throttle
screw on the valve. Locate the throttle screw on the
boiler being converted.
WARNING
Explosion Hazard.
Asphyxiation Hazard.
This conversion should be performed by a
qualified service agency in accordance with the
manufacturer’s instructions and all applicable
codes and requirements of the authority
having jurisdiction. If the information in these
instructions is not followed exactly, a fire, an
explosion or production of carbon monoxide
may result causing property damage, personal
injury, or loss of life. The qualified service
agency is responsible for proper conversion of
these boilers. The conversion is not proper and
complete until the operation of the converted
appliance is checked as specified in this manual.
2. If conversion is being made on a new
installation, install the boiler in accordance
with the installation instructions supplied with the
boiler. If an installed boiler is being converted,
connect the new gas supply to the boiler, check for
gas leaks, and purge the gas line up to the boiler
in accordance with the National Fuel Gas Code,
ANSI Z223.1/NFPA 54 and/or Natural Gas and
Propane Installation Code, CAN/CSA B149.1 or the
requirements of the authority having jurisdiction.
3.Before attempting to start the boiler, make the
number of turns to the throttle screw called for in
Table 37.
4. Start the boiler using operating instructions
in Figure 47. After the boiler is powered up with
a call for heat, the boiler should go through the
sequence of operation shown in Table 49. Even if
the gas line has been completely purged of air, it
may take several tries for ignition before a flame
is established. If more than 2 tries for ignition are
needed, it will be necessary to press the reset button
to restart the boiler. If boiler does not light, turn
the throttle screw counter-clockwise in 1/4 turn
increments, allowing the boiler to make at least
three tries for ignition at each setting, until the boiler
lights.
Table 37: Approximate Clockwise Throttle
Screw Turns for LP Gas (Propane)
Conversion
Boiler Model
APX425C
APX525C
APX625C
APX725C
APX825C
74
Approximate
Throttle Screw Turns
2¾
3
N/A - Factory LP Builds
IX. System Start-up (continued)
WARNING
Asphyxiation Hazard. The throttle adjustments
shown in Table 37 are approximate. The
final throttle setting must be found using a
combustion analyzer. Leaving the boiler in
operation with a CO air free level in excess of
200 ppm could result in injury or death from
carbon monoxide poisoning.
5. After the burner lights, complete all steps outlined
in Paragraph O “Perform Combustion Test” before
proceeding.
WARNING
Asphyxiation Hazard. These instructions
include a procedure for adjusting the air-fuel
mixture on this boiler. This procedure requires
a combustion analyzer to measure the O2 (or
CO2) and Carbon Monoxide (CO air free) levels in
flue gas. Adjusting the air-fuel mixture without
a proper combustion analyzer could result in
unreliable boiler operation, personal injury, or
death due to carbon monoxide poisoning.
6. Verify that the gas inlet pressure is between the
upper and lower limits shown in Table 33 with all
gas appliances (including the converted boiler) both
on and off.
7. A label sheet is provided with the boiler for
conversions from natural gas to LP gas. Once
conversion is completed, apply labels as follows:
a. Apply the “Rating Plate Label” adjacent to the
rating plate.
U. Correcting Throttle Screw Mis-Adjustment
(if required)
Apex boilers are fire tested at factory and gas valve
throttle screws are preset. However, if boiler does not
start when first turned on, and, the problem cannot
be remedied following “Help” prompts on the boiler
control display, it may be necessary to reset and
readjust the throttle screw according to the following
instructions.
1. Fully close throttle by turning throttle screw
clockwise until it fully stops.
2. Open throttle screw counter-clockwise the
number of full (360 degrees) and partial turns listed
in Table 38 for natural gas or Table 39 for LP gas.
3. Follow instructions in Paragraph O “Perform
Combustion Test” to verify O2 (or CO2) is within the
range specified in Table 35 for natural gas or Table
36 for LP gas at both high fire and low fire.
WARNING
The throttle adjustment values shown in Table 38
and Table 39 are approximate. The final throttle
setting must be found using a combustion
analyzer.
Table 38: Approximate Counter-Clockwise
Throttle Screw Turns from Fully Closed
Position, Natural Gas
Boiler
Model
Approximate
Throttle Screw Turns
APX425C
5¾
APX525C
6½
b. Apply the “Gas Valve Label” to a conspicuous area
on the gas valve.
APX625C
6½
APX725C
10½
c. Apply the “Boiler Conversion Label” to a
conspicuous surface on, or adjacent to, the outer
boiler jacket. Fill in the date of the conversion and
the name and address of the company making the
conversion with a permanent marker.
APX825C
11
Table 39: Approximate Counter-Clockwise
Throttle Screw Turns from Fully
Closed Position, LP Gas (Propane)
Boiler
Model
Approximate
Throttle Screw Turns
APX425C
3
APX525C
3½
APX625C
8
APX725C
12
APX825C
8½
75
IX. System Start-up (continued)
WARNING
Asphyxiation Hazard. If the throttle is very far out of adjustment on the “rich” (counter-clockwise) side,
the boiler burner may be running at 0% excess air or even with air deficiency. Operating the boiler in this
condition may cause property damage, personal injury or loss of life.
At 0% excess air the CO2 readings will be either 11.9% CO2 for natural gas or 13.8% CO2 for LP gas (O2 will
be 0%) and CO air free level will be extremely high (well over 1000 PPM).
If the burner operates with air deficiency, the following phenomena may be observed:
% CO2 will actually drop (% O2 will increase) as the throttle is turned counter-clockwise
% CO2 will actually increase (% O2 will drop) as the throttle is turned clockwise
If the boiler appears to operate with air deficiency, shut down the boiler and follow instructions in Paragraph
U “Correcting Throttle Screws Mis-Adjustment. Then, use a combustion analyzer to verify and adjust O2 (or
CO2) and CO air free to values shown in Table 35 for natural gas or Table 36 for LP gas.
V. Controls Start-up Check List
Check field wiring and control parameters per below Table 40 and Table 41. The control is factory programmed with default
parameters. Review parameters and adjust as necessary to conform to specific site requirements. From Home Screen, select
ADJUST to access below listed parameters. Login as needed to make changes. For detailed login instructions, refer to
Section X “Operation”, Paragraph J. Parameter Adjustment.
Table 40: Field Wiring Checklist
Step
Wiring Location
Parameter
120V Line
1
120V PCB
Description
Is line voltage connected with overcurrent protection?
Boiler, System, and
DHW Pumps
Confirm pumps are connected. If using room air for combustion,
confirm combustion air damper is connected.
Enable/Disable
Is the space heating thermostat connected. Ensure thermostat is
a “dry”, non-powered input.
DHW Demand
Is an indirect water heater (IWH) providing a heat demand?
Are external limits used? If so, ensure jumper is removed and
Auto Reset and Man
limits properly connected. Also check that external limits are
Reset External Limit
closed and any manual reset devices are reset.
Lockout Alarm
EnviraCOM
2
Low Voltage
Connections PCB
Are any EnviraCOM devices used?
Outdoor Sensor
Is an outdoor sensor used? Refer to Steps 1 & 7 in Table 41.
Header Sensor
Is a header sensor used? A header sensor is required for the
master boiler in a multiple boiler installation. Refer to Step 8 in
Table 41 to activate this input.
DHW Sensor
For single boiler servicing indirect water heater (IWH), install
DHW sensor at boiler-side inlet to IWH. Refer to Step 6 in Table
41 to activate this input.
Remote 4-20mA
Is a 4-20mA input required for: 1) modulation input from an
energy management system, or 2) Central Heat setpoint input
from external multiple boiler control? If yes, refer to Step 11 in
Table 41.
Boiler-to-Boiler
Are multiple boilers connected? If yes, refer to Steps 8 & 9 in
Table 41 to activate boiler-to-boiler communication.
EMS
Flow Switch
LWCO
76
Are alarm contacts connected?
Is the boiler connected to an energy management system? If yes,
refer to Step 10 in Table 41.
Is flow switch installed in piping and plugged in?
Is a 24V LWCO used? Check installation.
IX. System Start-up (continued)
Table 41: Control Parameter Checklist
Step
Parameter
Location
1
Adjust >>
System
2
Adjust >>
Modulation
3
Adjust >>
Pumps
Parameter
Outdoor Sensor Source
Warm Weather Shutdown
Enable/Disable
Boiler Model
Description
Select appropriate source: Not Installed, Wired, Wireless, or
Modbus.
Selecting Enable will restrict boiler start during warm weather, but
only if an outdoor sensor is installed.
WARNING
Confirm correct boiler model is shown. Stop installation and contact
factory if incorrect boiler model is shown.
Boiler Pump
System Pump
Ensure pump parameter selections are correct for your application.
Domestic Hot Water Pump
Contractor
Enter contact information. In the event of a fault, or the need
to adjust a setting, the display will direct the user to the entered
contact.
4
Adjust >>
Service Contacts
5
Adjust >>
Central Heat
6
Adjust >>
Domestic Hot Water
7
Adjust >>
Outdoor Reset
Enable/Disable
8
Adjust >>
Sequencer Master
Sequencer Master
If boiler is the master boiler in a multiple boiler installation, select
Enable.
9
Adjust >>
Sequencer Slave
Boiler Address
If boiler is a slave boiler in a multiple boiler installation, assign a
unique boiler address.
10
EMS >>
Modbus Setup
EMS Enable/Disable
If boiler is connected to an energy management system, select
Enable.
11
EMS >> Remote
Demand
Service Company
Sales Representative
Setpoint
Ensure target space heating water temperature (Setpoint) is correct
for your type of radiation.
Setpoint
Ensure target domestic hot water temperature (Setpoint) is correct.
DHW Modulation Sensor
Modulation Source
Central Heat Setpoint
Source
If using DHW Sensor, select DHW Sensor.
If not using an outdoor sensor, select Disable.
If using an external multiple boiler controller, set to 4-20 mA.
If an Energy Management System is sending a remote setpoint to
the boiler, set to 4-20 mA.
77
X. Operation
A. Basic Operation
When a call for heat is provided, the boiler attempts
to maintain a target supply (outlet) water temperature
or header temperature (if header sensor enabled).
The boiler control varies fan speed to modulate
boiler output. As fan speed changes, the gas valve
regulates fuel gas flow to match combustion air
flow, resulting in a relatively constant fuel: air ratio
across the modulation range. The control determines
required output by looking at both current and recent
differences between measured temperature and setpoint
temperature. As measured temperature approaches
setpoint temperature, the control reduces boiler output
by reducing fan speed. The control also looks at return
(inlet) water temperature and flue gas temperature when
determining modulation rate.
B. Features
1. Boiler Control
The Concert Boiler 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.
5. Warm Weather Shutdown
6. Pump Control
Boiler status and setup selections are available from
an easy to use, full color, Touch Screen Display.
In the event of a fault condition the user is guided
by blinking touch buttons to help screens that
explain the problem, cause, and corrective action.
Operation evaluation and problem-solving is
enhanced by historical capability including graphic
trends, lockout history records, as well as boiler and
circulator cycle counts and run time hours.
4. Outdoor Reset
78
When selected, outdoor reset automatically adjusts
supply water temperature based on outside air
temperature, time of day, and length of demand
(boost) settings for energy savings. Outdoor reset
requires installation of an outdoor sensor. Hardwired and wireless outdoor sensors are available.
The control includes state-of-the-art modulating
lead-lag sequencer for up to eight boilers capable
of automatic rotation, outdoor reset, and boiler-toboiler communication. Multiple boiler sequencing
requires plug-and-play connections between boilers.
Precise boiler coordination is provided as boilers are
sequenced based on both header water temperature
and boiler modulation rate. For example, the lead
boiler (Sequencer Master) can be configured to start
a lag boiler after operating at 50% modulation rate
for longer than an adjustable time. The boilers are
modulated in unison (parallel) modulation rate to
ensure even heat distribution.
8. Energy Management System (EMS)
Interface
3. Demand
Two demand inputs are provided on the low voltage
PCB: Enable/Disable for space heating (Central
Heat), and DHW Demand for domestic hot water
(DHW) or other heating demand. Enable/Disable
and DHW Demand each have unique temperature
and pump settings. In a multiple boiler installation,
the sequencer control may also provide demand.
Three pump outputs are provided on the 120V
PCB: Boiler Pump, System Pump, and DHW Pump.
Outputs are service rated relays. Simple parameter
selections allow all three pumps to respond properly
to various hydronic piping arrangements. To help
prevent rotor seizing, pumps are automatically run
for a 20 second exercise period after not being used
for longer than seven days.
7. Multiple Boiler Sequencer Boiler-to-Boiler
Network
2. Advanced Touch Screen Display
Some boilers are used primarily for heating
buildings, and the boilers can be automatically
shut down when outdoor air temperature is warm.
When outside air temperature is above the WWSD
setpoint, this function will shut down the boiler and
system pump.
The control accepts a 4-20mA DC input from an
energy management system (EMS) for either direct
modulation rate or temperature setpoint. A factory
configured RS485 Modbus interface is available for
EMS monitoring, which can be used in conjunction
with the multiple boiler sequencer.
9. Archives via USB Thumb Drive
Archives allow easy transfer of parameters
from one boiler to another using a USB thumb
drive. Additionally, Archives are a valuable
troubleshooting tool, providing alarm history and
operating history in spreadsheet (.csv) format
downloaded to a thumb drive.
X. Operation (continued)
C. Supply (Outlet) Water Temperature
Regulation
1. Priority Demand
When more than one demand is present, the higher
5. Boost Time
When the Central Heat Setpoint is decreased by
Outdoor Reset settings, the Boost function can
be enabled to increase the setpoint in the event
that central heat demand is not satisfied for longer
than the Boost Time minutes. The Boost function
increases the active setpoint by 10°F for every 20
minutes (field adjustable) the central heat demand
continues unsatisfied. This process continues
until central heat demand is satisfied, after which
operating setpoint reverts to value determined by
Outdoor Reset settings. Boost function is not used
if Boost Time is zero.
priority demand is used to determine boiler settings
as shown in Table 42. For example, when DHW
priority is enabled, the setpoint, difference above,
difference below and pump settings are taken from
DHW selections. Active priority is displayed on the
Home Screen (see Figure 51).
Table 42: Order of Priority
Priority
Demand
1
Sequencer
Control
2
Domestic
Hot Water
3
Central
Heat
4
Frost
Protection
5
Warm
Weather
Shutdown
(WWSD)
Boiler Responding to:
The boiler is connected in a boiler-to-boiler
network. The boiler accepts demand from
the Sequencer Master boiler.
DHW Demand is on and selected as the
priority demand. DHW Demand is always
higher priority than Central Heat. DHW
Demand also has higher priority than the
Sequencer Control when DHW priority is
enabled (Priority Time greater than zero)
and DHW Pump is set to Boiler Piped IWH.
Enable/Disable is on and there is no DHW
demand or DHW priority time has expired.
Frost Protection is active and there is no
other call for heat. Frost protection will be
a higher priority than Sequencer Control
if the Sequence Master has no active call
for heat.
DHW Setpoint or DHW Time of Day Setpoint (if
thermostat is in Sleep or Away mode). The optimal
value is based on requirements of the specific
indirect water heater (if used).
7. Domestic Hot Water (DHW) Priority
If Domestic Hot Water Priority Time is greater than
zero and there is a DHW demand, the system pump
will be turned off (with System Pump parameter set
to Central Heat, No Priority) and the DHW pump
will be turned on. Additionally, if Outdoor Reset is
enabled, the active setpoint is adjusted to the DHW
Setpoint. Priority protection is provided to ensure
Central Heat supply in event of an excessively long
DHW demand.
WWSD is active and the boiler will not
respond to Enable/Disable. DHW Demand
is not blocked by WWSD.
2. Setpoint Purpose
6. Domestic Hot Water (DHW) Setpoint
With DHW demand, the active setpoint is either the
The control starts, stops, and modulates boiler
output from minimum to maximum to heat water up
to the active setpoint. Active setpoint is determined
by priority as shown in Table 42.
8. Time of Day (Setback) Setpoints
3. Central Heat Setpoint
With Enable/Disable demand, the active setpoint is
either the Central Heat Setpoint, Central Heat Time
of Day Setpoint (if thermostat is in Sleep or Away
mode), Outdoor Reset setpoint, or a value set by
4-20mA input from an energy management system
(EMS).
4. Outdoor Reset
If an outdoor sensor is connected to the boiler and
outdoor reset is enabled, the Central Heat Setpoint
will automatically adjust downwards as the outdoor
temperature increases. Room air temperature
overshoot is minimized since water temperature
is properly matched to heating needs. Outdoor
reset saves energy by reducing room overheating,
reducing boiler temperature, increasing efficiency,
and reducing standby losses as boiler and system
piping cool down to ambient following a heating
cycle.
User-adjustable Time of Day Setpoints are provided
for both Central Heat and DHW demands to save
energy when a building is unoccupied. Time of
Day Setpoints are active when an EnviraCOM
thermostat is connected to the boiler and is in Sleep
or Away mode. Example EnviraCOM thermostat:
Honeywell VisionPro IAQ, model TH9421C1004.
D. Boiler Protection Features
1. Supply Water Temperature High Limit
The boiler is equipped with a UL 353 listed boiler
control and UL 1434 listed high limit sensor.
Default response to supply temperature is as
follows.
• Supply exceeds 190°F (87.7°C) – output (fan
speed) reduced
• Supply exceeds 200°F (93.3°C) – recycle
• Supply exceeds 210°F (98.9°C) – manual reset
hard lockout
Additionally, a soft lockout occurs if the supply
temperature rises to fast (i.e. faster than the degrees
Fahrenheit per second limit). Output reduced and
recycle responses are inactive for a stand-alone
79
X. Operation D. Boiler Protection Features (continued)
boiler without a header sensor. Temperatures are
field adjustable except manual reset hard lockout
cannot exceed 210°F (98.9°C).
7. Automatic Reset Limit Devices
2. High Limit Differential Temperature Limit
The control monitors temperature difference
between return and supply sensors. Default
response to temperature difference is as follows.
• Differential exceeds 43°F (23.9°C) – output (fan
speed) reduced
• Differential exceeds 53°F (29.4°C) –
recycle • Differential exceeds 63°F (35°C) – shutdown;
automatic restart after temperature difference has
decreased and minimum off time has expired
3. Return Temperature Higher Than Supply
Temperature (Inversion Limit)
If return water temperature exceeds supply water
temperature for longer than a limit time delay, the
control shuts down the boiler and delays restart. If
the inverted temperature is detected more than five
times, the boiler shuts down with a hard lockout.
Condition is caused by incorrect supply and return
piping connections.
4. Flue Temperature High Limit
The control monitors flue gas temperature sensor
located in vent outlet at rear of heat exchanger.
Response to flue temperature is as follows:
• Flue exceeds 184°F (84.4°C) – output (fan
speed) is reduced
• Flue exceeds 194°F (90.0°C) – recycle
• Flue exceeds 204°F (95.6°C) – manual reset hard
lockout
Temperature is field adjustable except manual reset
hard lockout cannot exceed 204°F (95.6°C).
5. Flow Switch
The flow switch shuts down the boiler when there
is insufficient water flow in the boiler primary loop.
When water flow is restored to a boiler-specific
minimum value (see Table 24), the flow switch
detects flow and automatically restarts the boiler.
The flow switch is required and is factory provided.
If any below listed limit opens, the boiler shuts
down and provides an open limit indication. The
boiler will automatically restart once the limit
closes. An external limit control with its own
manual reset button requires pressing external limit
reset button after limit closes even when connected
to Auto Reset External Limit terminals.
• Sump pressure switch – opens if inadequate air
flow is detected during operation
• Condensate float switch – opens if condensate
drain is blocked
• 24V LWCO (if used) – opens if low water
condition is detected
• Device(s) connected to Auto Reset External
Limit terminals
8. Manual Reset Limit Devices
If any below listed limit opens, the boiler shuts
down, provides an open limit indication, and closes
the Lockout Alarm contact. The boiler will restart
only after the limit closes and the boiler control
manual reset button is depressed. During boiler start
sequence, air proving switch must prove open before
blower starts and closed after blower starts. If air
proving switch is not in the required position, the
control waits for a preset time period and then shuts
down with a manual reset hard lockout.
• Thermal link – opens if rear of combustion
chamber overheats; one time use device
• Burner door thermostat – opens if burner door
overheats, manual reset button on thermostat
• High and low gas pressure switches (if used, size
525-825 only) – open if gas pressure is outside of
preset limits, manual reset button on each switch
• Air proving switch – opens if inadequate air flow
is detected prior to ignition
• Device(s) connected to Man Reset External
Limit terminals
6. Ignition Failure
80
The control monitors ignition using a burner
mounted flame sensor. Response on ignition failure
is as follows:
• Size 425: retries five times, then soft lockout for
one hour
• Size 525-825: retries one time, then manual
reset hard lockout
Figure 50: Limit String Status Screen Showing
Central Heat Demand
X. Operation (continued)
Table 43: Limit String
Limit String
Type
STAT
A1
A2/LCI
ILK
Description
Action
“ON” indicates heat demand and enables control to fire to maintain water temperature at setpoint.
• Heat demand may be received from “Enable/Disable” terminals for Central Heat Demand, “DHW Demand”
Heat Demand
terminals for DHW Demand, the Sequencer Master, or EMS Modbus inputs.
• Heat Demand input “ON” initiates pump and combustion air damper outputs.
A1 is the air proving switch and must cycle “ON” and “OFF” at appropriate times in order for boiler to start.
• A1 must prove “OFF” before blower starts. A1 “ON” before blower starts causes manual reset hard lockout
Annunciator 1
after a delay.
• A1 must prove “ON” after blower starts and before trial for ignition. A1 “OFF” during this time causes manual
reset hard lockout after a delay.
A2 limits are upstream of and connected in series with LCI limits. LCI must prove “ON” for boiler to start. Boiler
Annunciator 2/ will shut down if LCI is turned “OFF” during operation.
Load Control • Hold message shown when LCI limit is “OFF” and Heat Demand is “ON”.
Input
• LCI Hold will never cause a manual reset lockout.
• Boiler may be disabled remotely by wiring an enable contact to the LCI “External Limit” terminals.
Interlock
ILK must prove “ON” for boiler to start. Boiler will shut down with manual reset hard lockout if ILK is turned
“OFF” during operation. ILK OFF Lockout closes the Lockout Alarm contacts.
9. Central Heating System Frost Protection
When enabled, Frost Protection starts the boiler and
system pump and fires the boiler when low outside
air and low supply water temperatures are sensed.
The Control provides the following control action
when frost protection is enabled:
Table 44: Frost Protection
Device
Started
Boiler Pump
Boiler
Start
Temperatures
Frost Protection NOTE
The Control helps provide freeze protection for the boiler
water. Boiler flue gas condensate drain is not protected from
freezing. Since the Control only controls the system and
boiler circulators individual zones are not protected. It is
recommended that the boiler be installed in a location that is
not exposed to freezing temperatures.
Stop
Temperatures
Outside Air < 0°F ° (-18°C)
Outside Air > 4°F (-16°C)
or Supply Water < 45°F (7.2°C) or Supply Water > 50°F (10°C)
Supply Water < 38°F (3.3°C)
Supply Water > 50°F (10°C)
E. Touch Screen Display Navigation
1. HOME SCREEN is the default state for the display, shown in Figure 51. The home screen displays basic operating
information and provides access to other screens through icons at the top of the screen.
Figure 51: Home Screen
81
X. Operation E. Touch screen display Navigation (continued)
2. MAIN MENU provides access to all display functions. It is accessible from the Home Screen. The following major
user interface areas are accessed from the Main Menu:
Figure 52: Main Menu Screen
a. STATUS provides a “walk” through boiler
operation. These screens provide an overview
of boiler and networked boiler operation. Status
screens include “Load Profile” for Central Heat
and Domestic Demands. These profiles allow
the user to review the Run Hour (%) versus Load
(%). The “Load Profile” along with run hours
and cycles provides a complete picture of boiler
status.
b. OPERATION screens allow the user to take
manual or automatic control of the unit. These
screens are intended to allow a technician to set
firing rate to support combustion testing and
provide trending and parameter adjusting to
support fine tuning the boilers response to load
changes. Operation screens may be used to
speed up or slow down the boilers response to
fast or slow system load changes.
82
c. ARCHIVES collect history of how the boiler
has operated and provide tools to review and
improve system operation.
i. Historical Trend – Up to four (4) months
of data is collected and may be viewed
on screen or saved to a Thumb Drive.
ii. Lockout History – provides data on
up to 15 manual reset Lockouts. Data
collected includes cause of boiler
trip, run hour and status when lockout
occurred.
iii. Cycle & Run Time History – collects the
usual summary of cycles and hours of
boiler and pump operation. All cycles
and run hours other than the controller
quantities may be reset to aid in
identifying improvements made.
iv. Alarm History – limit string faults, holds,
manual reset lockouts and other alarms
are recorded with time and date stamp.
v. Thumb Drive Operation – these screens
provide ability to save or load parameters
as well as alarm and trend data.
d. SENSORS provides status and details on all
sensors connected to the control.
e. EMS allows the user to access setup options and
status for an energy management system (EMS).
f. HELP displays active alarms and corrective
actions.
g. QUICK SETUP presents commonly required
parameters for quick review and adjustment.
h. ADJUST presents each adjustable parameter
for adjustment. Proper login is required.
F. Quick Setup
Quick Setup is accessed from the Main Menu. Quick
Setup allows the user to review and adjust the most
commonly adjusted parameters, such as setpoints
and pump output settings, from one location. Refer
to Parameter Adjustment section for additional
information.
Table 45: Setpoints
Factory
Setting
(°F)
Range /
Choices
(°F)
180
50 to 190
Central Heat Difference Above
7
2 to 25
Central Heat Difference Below
5
2 to 25
Domestic Hot Water Setpoint
Parameter and Description
Central Heat Setpoint
170
50 to 190
Domestic Hot Water Difference Above
7
3 to 29
Domestic Hot Water Difference Below
5
3 to 29
Frost Protection Setpoint
0
-50 to 50
Warm Weather Shutdown Setpoint
70
20 to 100
Stop All Boilers
195
50 to 195
X. Operation F. Quick setup (continued)
Table 46: Hydronic System
Parameter
and
Description
Factory
Setting
Range / Choices
Boiler Pump
Any Demand
Never, Any Demand
Central Heat, OFF DHW Demand
Header Sensor Demand/
Combustion air Damper
System Pump
Any Demand
DHW Pump
Primary Loop
Piped IWH
Never
Any Demand
Central Heat, No Priority
Central Heat, Optional Priority, Fresh Air Damper
Never
Primary Loop Piped IWH
Boiler Piped IWH, Fresh Air Damper
Table 47: Comfort Settings
Parameter and Description
Factory
Setting (°F)
Range /
Choices (°F)
0
-50 to 32
Minimum Outdoor Temperature
Maximum Outdoor Temperature
70
35 to 100
Low Water Temperature
110
70 to 180
Minimum Boiler Water Temperature
130
50 to 185
Table 48: Response Speed
Parameter and Description
Factory Setting
Central Heat Response Speed
Range / Choices
3
1 to 5
120 seconds
0 to 1800 seconds
3
1 to 5
Domestic Low Fire Hold Time
10 seconds
0 to 1800 seconds
Sequencer Response Speed
3
0 to 5
Central Heat Low Fire Hold Time
Domestic Response Speed
Table 49: Sequence of Operation
Status
Standby
Description
Boiler is not firing. Appropriate circulators are on if Priority is not Standby. With a central heat demand,
sequence proceeds from Standby when supply temperature drops below Setpoint minus Difference Below.
Safe Startup
Flame circuit is tested.
Drive Purge
Blower is driven to purge speed.
Prepurge
Combustion chamber is purged for 10 s after reaching purge speed.
Drive Lightoff
Blower is driven to lightoff speed.
Preignition Test
Control conducts safety relay test.
Preignition
Direct Ignition
Running
Postpurge
Spark is energized and it is confirmed that no flame is present.
Spark and gas valve are energized.
After flame is proven, sequence continues with run stabilization and, when selected, low fire hold time and
slow start ramp. Once field adjustable low fire hold time and ramp rate is completed, normal boiler operation
begins with modulation rate dependent on temperature and setpoint selections.
When the call for heat ends, gas valve is closed. Combustion chamber is purged for 10 s after blower
reaches postpurge speed.
83
X. Operation (continued)
Figure 53: Sequence of Operation
G. Sequence of Operation
Boiler status is shown in the lower right corner of the Home Screen (see Figure 51). After limits have been established, the
boiler sequence progresses as shown in Table 49 and Figure 53.
Figure 54: Home Screen Details
84
X. Operation (continued)
H. Status Screens
3. Demand Status
Boiler status screens are the primary boiler monitoring
screens. The user may simply “walk” through boiler
operation by repeatedly selecting the right or left
“arrow” symbol. To access these screens, select
STATUS from the Home Screen or Main Menu. See
Figure 55 for screen navigation and Figure 56 for
screen detail.
1. Sequencer Status
This screen only appears when the Sequencer
Master is enabled. It shows data involved with
the network including active setpoint and sensor,
the network priority, and the setpoint source. This
status screen also displays all boilers in the boiler
to boiler network. The status screen displays each
boiler’s assigned boiler number, current state, firing
rate, and whether it is the current lead boiler.
2. Boiler Status
4. Boiler Monitoring
This is an overview of all sensors installed on the
boiler represented as bar graphs. Numeric values are
also provided for accurate readings.
5. Hydronic Trending
This screen gives an overview of the current status
of the boiler. The active setpoint and sensor which
the boiler is currently modulating based on are
displayed using a bar graph & numeric values.
Also displayed are all current sensors installed in
the boiler. These sensors will display red if there is
an issue with any of them. Additional information
shown includes current firing rate, boiler priority,
current status, and setpoint source.
This screen gives the demand status of the Central
Heat, Domestic Hot Water, and Sequencer (Lead
Lag). Along with this status, the boiler run hours,
on/off status, and cycles are also shown. Pump
information is also provided, including on/off status
and cycles. Frost Protection status and Exercise
will also appear when used. Additionally, the Load
Profiles are on this page, which give historic data
on the modulation of the boiler. This graph shows
the percent of the total run hours the boiler spends
modulating at each rate (%).
This screen allows the user to view from one to five
variable trends. Selecting the check mark enables a
variable to be added or removed from the trend.
Figure 55: Status Screen Navigation
85
X. Operation H. Status Screens (continued)
Figure 56: Status Screen Detail
86
X. Operation (continued)
I. Manual Operation and Tuning
Select Main Menu >> Operation to access the
Operation screen shown in Figure 57. From the
Operation screen, the user may manually adjust firing
rate or exercise pumps, access a service trend, or tune
the boiler.
NOTICE
When finished using manual mode, be sure
to select Automatic to return boiler to normal
operation. Otherwise the control will remain
in Manual mode for one hour, or until power is
cycled.
J. Parameter Adjustment
1. Entering Adjust Mode
NOTICE
Parameter adjustment may be performed only by
a qualified service technician.
Control operation may be tailored to suit the
application by adjusting parameters. To adjust
parameters, select the ADJUST icon located
throughout the display.
Press ADJUST icon to review and
adjust all parameters.
Parameters are password protected to discourage
unauthorized or accidental changes to settings. User
login is required to adjust these settings. Parameters
are locked and login requirement is shown when the
padlock icon is not green.
• Press the Lock icon to access password screen.
• Use keypad to enter password.
• Press Enter Key when complete.
Figure 57: Operations Screen
1. Bar Graph & Trend – Shows active sensor,
active setpoint, and modulation.
2. Automatic/Manual Firing Rate Control –
User may adjust modulation manually. Menu also
allows for switching of units from % (default) to
RPM.
3. High/Low – Allows user to drive boiler to high or
low fire when Manual Modulation is selected.
4. Service Trend – Shows boiler temperatures, firing
rate, and demand statuses.
5. Tune – Allows for adjustment of parameters related
to the rate of boiler response. This includes PID
settings, ramp rates and more. Refer to Paragraph J,
14 for more details.
6. Manual Pump Exercise – Allows pumps to
be set to either ON or Automatic. When ON
is selected, pump will run. When Automatic is
selected, pump will follow settings assigned in
Pumps menu.
Figure 58: Entering Adjust Mode
NOTICE
A USB thumb drive may be used to transfer
parameters from one boiler to another. See
Paragraph K, “USB Thumb Drive Parameter
Transfer”.
87
X. Operation J. Parameter Adjustment (continued)
2. Adjusting Parameters
After entering the password, editing parameters is
accomplished as follows:
Figure 59: Adjusting Parameters
3. System Parameters
Select
to access the following parameters.
Parameter and Description
Temperature Units
Factory Setting
Range / Choices
Fahrenheit
Fahrenheit,
Celsius
Outdoor Sensor Source
Not Installed
Outdoor Sensor is not connected to the boiler. Sensor is not
monitored for faults.
Wired
Outdoor Sensor is wired to boiler low voltage PCB.
Modbus
Outdoor temperature is retrieved through the Modbus connection from
another boiler or Energy Management System.
Wireless
Wireless outdoor sensor is installed. Honeywell Wireless Outdoor Air
Reset Adapter part number 105766-01 is a wireless outdoor air
sensor. The package includes a Wireless Receiver Module and
Wireless Outdoor Sensor. The sensor communicates wirelessly to the
receiver module. The receiver module is wired to the low voltage
PCB EnviraCOM terminals. Refer to wiring section for more
information.
Wired
Not installed,
Wired,
Modbus,
Wireless
Outdoor Sensor Calibration
Outdoor sensor calibration allows a single point adjustment of the outdoor sensor
reading. This adjustment is a correction offset added to or subtracted from the outdoor temperature sensor reading. It is recommended to make any calibration when
outdoor air temperature is at or near the most common operating point. For example,
when necessary, calibrate the sensor when outdoor air is halfway between Minimum
and a Maximum Outdoor Temperature parameter value is recommended.
0 degrees
-50 + 50°F
tenths of degree
(-45.6 to 10°C)
Anti-short Cycle Time
Anti-short cycle is a tool that helps prevent excessive cycling resulting from a fast
cycling enable-disable input. It provides a minimum delay time before the next burner
cycle. DHW demand is serviced immediately, without any delay.
0 min.
0 - 20 min.
88
X. Operation J. Parameter Adjustment (continued)
3. System Parameters (continued)
Parameter and Description
Installer’s Password
Allows for custom password to be set. Must be 9 characters or less. Only
allows adjustment of supervisor password (supervisor default: 76). Cannot
change factory password.
• Must enter current installer password.
• Must enter new password and press enter.
• Must re-enter new password and press enter.
• Can be reset to supervisor default 76 if accessed with the Factory
level password (86).
CH Frost Protection
Disable Frost Protection is not used.
Enable Boiler and system circulators start and boiler fires when low out
side air, supply and return temperatures are sensed as follows:
Device
Started
Boiler Pump
Boiler
Start
Temperatures
Stop
Temperatures
Factory Setting
Range / Choices
76
9 Character
Maximum
Enable
Enable, Disable
0°F (-18°C)
-50 to 50 (ºF)
(-45.6 to 10.0°C)
Disable
Enable, Disable
70°F
(21.1°C)
20 to 100°F
(-6.7 to 37.8°C)
Enabled
Enable/Disable
xx/xx/xxxx
N/A
xx:xx:xx
N/A
Outside Air < 0°F ° (-18°C)
Outside Air > 4°F (-16°C)
or Supply Water < 45°F (7.2°C) or Supply Water > 50°F (10°C)
Supply Water < 38°F (3.3°C)
Supply Water > 50°F (10°C)
CH Frost Protection Setpoint
Outdoor Temperature at which pump is started for frost protection.
Warm Weather Shutdown Enable/Disable
Disable Warm Weather Shutdown (WWSD) is not used.
Enable A central heat boiler start is prevented if the outside temperature
is greater than the WWSD setpoint. WWSD is initiated as soon
as outside air temperature is above WWSD Setpoint. The control
does not require call for heat to be satisfied before entering
WWSD. The boiler will still start in response to a Domestic Hot
Water call for heat.
Warm Weather Shutdown Setpoint
The Warm Weather Shutdown (WWSD) Setpoint used to shut down the
boiler when enabled by the “WWSD Enable” parameter.
Auto Jump to Home Page
Enable After 15 minutes of no use, the display will automatically return to
the Home Page.
Disable Display will not change screens to Home Page after 15 minutes.
System Date
Date used by display Alarm History screen. A battery is provided to maintain
the system date and time while the display is powered down.
System Time
Time used by display Alarm History screen. A battery is provided to maintain
the system date and time while the display is powered down.
89
X. Operation J. Parameter Adjustment (continued)
4. Modulation Parameters
WARNING
Asphyxiation Hazard. Boiler type is factory set and must match the boiler model. Only change the boiler
type setting if you are installing the boiler at altitudes above 2000 ft or if you are replacing the 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.
Select
to access the following parameters.
Parameter and Description
Factory
Setting
Range / Choices
Boiler Model
To verify the boiler model selection, a qualified technician should do the following:
1. Check boiler’s label for actual boiler model.
2. Set “Boiler Model” to match actual boiler model.
3. Select “Confirm”.
The Boiler Model parameter changes the minimum and maximum modulation
settings. This parameter is intended to allow a user to set parameters for altitudes
above 2000 ft or in a spare part control to a particular boiler model. See Figure 60.
varies by model
see Figure 60
CH Max Modulation Speed
This parameter defines the highest modulation rate the control will go to during a
central heat call for heat. If the rated input of the installed radiation is less than the
maximum output of the boiler, change the Central Heat Maximum Modulation (fan
speed) setting to limit the boiler output accordingly.
varies by model
Minimum to Maximum
Modulation
DHW Max Modulation Speed
This parameter defines the highest modulation rate the control will go to during a
Domestic Hot Water call for heat. If the rated input of the indirect water heater is
less than the maximum output of the boiler, change the DHW Maximum Modulation
(fan speed) setting to limit the boiler output accordingly.
80% of CH
Maximum
Modulation
Speed
Minimum to Maximum
Modulation
Minimum Modulation Speed
This parameter is the lowest modulation rate the control will go to during any call
for heat.
varies by model
Minimum to Maximum
Modulation
Lightoff Rate
This is the blower speed during ignition and flame stabilization periods.
varies by model
425: 3,500-4,000 rpm
525-825: non-adjustable
NOTICE
If boiler is being installed at elevation above 2000 ft, refer to Appendix A: Instructions for High Altitude
Installations Above 2000 ft.
Figure 60: Boiler Model (Boiler Type) Decoding
90
X. Operation J. Parameter Adjustment (continued)
5. Pump Parameters
Select
to access the following parameters.
Parameter and Description
Factory
Setting
System Pump
Activates system pump output according to selected function:
Never:
Pump is disabled and not shown on status screen.
Any Demand:
Pump runs for any demand.
Central Heat, No Priority: Pump runs during central heat and frost protection
demand. Pump does not start for a DHW demand and
continues to run during DHW Priority.
Central Heat, Optional
Priority:
Range / Choices
Never
Any Demand
Any Demand
Central Heat, No Priority
Central Heat, Optional
Priority
Pump Runs during central heat and frost protection
demand. Pump does not start for a DHW demand and will
be forced off if there is a DHW demand and DHW Priority
is active.
Fresh Air Damper
Boiler Pump
Activates boiler pump and combustion air damper (if using room air) output according to selected
function:
Any Demand:
Central Heat, off DHW
Demand:
Header Sensor/
Combustion Air Damper:
Pump runs/damper opens for any demand.
Make sure indirect water heater and DHW circulator are
sized to maintain flow through boiler within limits shown in
Table 24. Pump runs during central heat and frost
protection call for heat and will be forced off if there is a
DHW call for heat and DHW priority is active.
Never
Any Demand
Any Demand
Pump runs when boiler is firing to satisfy any call for heat.
Used when header sensor is enabled to prevent
unnecessary operation of boiler pump. Also used when
combustion air damper is wired to Boiler Pump output.
NOTE: Header Sensor must be used when combustion air
damper output is required.
Header Sensor Demand/
Combustion Air Damper
DHW Pump
Activates domestic hot water pump output according to selected function:
Never:
Never
Pump is disabled and not shown on status screen.
Primary Loop Piped IWH: Pump runs during DHW demand. DHW Priority enable/
disable does not affect pump operation.
Boiler Piped IWH:
Make sure indirect water heater and DHW circulator are
sized to maintain flow through boiler within limits shown in
Table 24. Pump runs during DHW demand. Pump is
forced off during central heat demand when 1) DHW
Priority is disabled or 2) DHW priority is enabled and
DHW demand has remained on for longer than Priority
Time.
Overrun Time: System Pump
Time that pump runs after demand is satisfied. Used to dissipate heat within the system.
Central Heat, off DHW
demand,
Primary
Loop Piped
IWH
Primary Loop Piped IWH
Boiler Piped IWH
Fresh Air Damper
0 min.
0 to 60 min.
Overrun Time: DHW Pump
Time that pump runs after demand is satisfied. Used to dissipate heat within the system.
0 min.
0 to 60 min.
Overrun Time: Boiler Pump/Combustion Air Damper
Time that pump runs after demand is satisfied. Used to dissipate heat within the system.
30 seconds
0 to 60 min.
7 days
0 to 40 days
20 seconds
0 to 10 min.
Pump Exercise Interval
The number of days the pump is inactive before the pump will be activated for the Pump Exercise Time.
Pump Exercise Time
The amount of time the pump runs for exercise. This feature helps prevent pump seizing due to
inactivity periods.
91
X. Operation J. Parameter Adjustment (continued)
6. Example Pump Parameter Selections
Single boiler, No Indirect Water Heater
Parameter Selections:
System Pump= “any demand”
Boiler Pump = “any demand”
DHW Modulation Sensor = “DHW Sensor”
DHW Pump = “never”
Explanation:
This piping arrangement only services
central heat. When there is any
demand both boiler and system
pumps turn on.
Single Boiler, Primary Piped Indirect Water Heater, Optional DHW 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.
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.
92
X. Operation J. Parameter Adjustment (continued)
Multiple Boilers, Boiler Piped Indirect Water Heater
Sequencer Master
(Boiler 1)
Boiler 2
Wiring locations:
Enable/Disable
X
DHW Demand
X
System pump
X
DHW pump
X
Boiler Pump
X
X
Sequencer Master Parameter Selections:
Sequencer Master
Indirect Water
Heater
Enabled
“Boiler Piped”
Pump Parameter Selections:
Central Heat,
No Priority
Never
Boiler Pump =
Central Heat,
Off DHW Priority
Any
demand
DHW Pump =
Boiler Piped IWH
Never
System Pump =
Explanation:
Make sure indirect water heater and DHW pump are sized to maintain flow though boiler within limits shown in Table 24.
This piping arrangement does not allow both the Slave 1’s boiler and domestic hot water pump to run at the same time.
When call for Domestic Hot Water is received the DHW pump is turned on and the boiler pump is turned off. However, the
system pumps may run to satisfy a central heat demand that is being satisfied by a different slave. The central heat demand
is ignored by Slave 1 until the domestic hot water demand is ended. If domestic hot water priority is enabled and priority
protection time is exceeded the domestic hot water pump turns off to allow the boiler pump to run.
Multiple Boilers, Primary Piped Indirect Water Heater, Optional DHW Priority
Sequencer Master
(Boiler 1)
Boiler 2
Wiring locations:
Enable/Disable
X
DHW Demand
X
System pump
X
DHW pump
X
Boiler Pump
X
X
Sequencer Master Parameter Selections:
Sequencer Master
Indirect Water
Heater
Enabled
“Primary Piped”
Pump Parameter Selections:
Central Heat,
Optional Priority
Never
Boiler Pump =
Any demand
Any
demand
DHW Pump =
Primary Loop
Piped IWH
Never
System Pump =
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.
93
X. Operation J. Parameter Adjustment (continued)
Example Pump Parameter selections (continued)
Multiple Boilers, Primary Piped Indirect Water Heater, System Pump Run for Any Demand
Sequencer Master
(Boiler 1)
Boiler 2
Wiring locations:
Enable/Disable
X
DHW Demand
X
System pump
X
DHW pump
X
Boiler Pump
X
X
Sequencer Master Parameter Selections:
Sequencer Master
Indirect Water
Heater
Enabled
“Primary Piped”
Pump Parameter Selections:
System Pump =
Any demand
Never
Boiler Pump =
Any demand
Any demand
DHW Pump =
Primary Loop
Piped IWH
Never
Explanation:
This piping arrangement requires the system pump to be running for any calls for heat. Also the boiler pump must run for any
call for heat.
7. Service Contacts
This information may be entered from a USB thumb drive or from the screen. Refer to Paragraph K. “USB Thumb Drive
Parameter Transfer”. USB Port Parameter Transfer for thumb drive instructions.
Select
to access the following parameters.
Parameter and Description
Factory Setting
Contractor
Select the line of information to
edit. Use key pad to input data
and press ENT to enter data into
Contractor Info.
Enter name
Enter address line 1
Enter address line 2
Enter phone number
Enter email
Service Company
Select the line of information to
edit. Use key pad to input data
and press ENT to enter data into
Service Company Info.
Enter name
Enter address line 1
Enter address line 2
Enter phone number
Enter email
Sales Representative
Select the line of information to
edit. Use key pad to input data
and press ENT to enter data into
Sales Representative Info.
Enter name
Enter address line 1
Enter address line 2
Enter phone number
Enter email
94
X. Operation J. Parameter Adjustment (continued)
8. Central Heat Parameters
Select
to access the following parameters.
Parameter and Description
Factory Setting
Range / Choices
Central Heat Setpoint
Target temperature for the central heat priority. Value also used by the outdoor air
reset function.
180°F
(82.2°C)
50 to 190°F
(10 to 87.8°C)
Time of Day Setpoint
Used when an EnviraCOM thermostat is connected to the boiler and is in Sleep or
Away mode. When setback is “on” the time of day setback setpoint shifts the reset
curve to save energy while building is in a reduced room temperature mode. The
reset curve is shifted by the difference between the High Boiler Water Temperature
and the TOD Setback Setpoint.
170°F
(76.7°C)
50 to 190°F
(10 to 87.8°C)
Difference Above
The boiler stops when the water temperature rises ‘Difference Above’ degrees above
the setpoint.
10°F
(-12.2°C)
2 to 25°F
(-16.7 to -3.9°C)
Difference Below
The boiler starts when the water temperature drops ‘Difference Below’ degrees below
the setpoint.
5°F
(-15°C)
2 to 25°F
(-16.7 to -3.9°C)
Response Speed
This parameter adjusts the Central Heat temperature controller Proportion Integral
Derivative (PID) values. Higher values cause a larger firing rate change for each
degree of temperature change. If set too high firing rate “overshoots” required value,
increases to high fire causing the temperature to exceed the “Difference Above”
setpoint and cycle the boiler unnecessarily. Lower values cause a smaller firing rate
change for each degree of temperature change. If set too low, the firing rate response
will be sluggish and temperature will wander away from setpoint. Refer to Table 50
for PID values used by these selections.
3
1 to 5
Central Heat Low Fire Hold Time
“Low Fire Hold Time” is the time the control will wait at low fire modulation rate before
being released to modulate. After ignition and flame stabilization periods, firing rate
is held at low fire for “Low Fire Hold Time”. This delay allows heat to travel out to the
system and provide system feedback prior to the control modulating firing rate.
120 seconds
0 to 1800 seconds
CH Modulation Sensor
Determines which temperature sensor the boiler responds to with Central Heat
demand. Outlet Sensor is the boiler’s internal supply sensor. When Header Sensor
is selected the boiler is fired in response to the sensor wired to Header Sensor
terminals. NOTE: When Header Sensor is selected, also set Boiler Pump parameter
to Header Sensor / Combustion Air Damper.
Outlet Sensor
Outlet Sensor
Header Sensor
95
X. Operation (J. Parameter Adjustment continued)
Table 50: Response Speed Adjustment Guidelines
9. Domestic Hot Water Parameters
Select
to access the following parameters.
Parameter and Description
Factory Setting
Range / Choices
Priority Time
When Priority Time is greater than zero and Domestic Hot Water (DHW) heat
demand is “on”, DHW demand will take “Priority” over Central Heat (space heating)
demand. When the System and Boiler pumps are configured as “Central Heat (off
DHW priority)” or “Central Heat, Optional Priority” then they will be forced “off” during
Priority Time. Priority Time provides “Priority Protection” time for the event of a failed
or excessive long DHW demand. “Priority Time” is the time that the priority of the
boiler will shift away from Central Heat to satisfy a Domestic Hot Water call for heat.
60 min
0 to 90 min
Setpoint
Setpoint is used to create a boiler water temperature setpoint that is used when DHW
heat demand is “on”. When the DHW heat demand is not “on” (i.e. the contact is open
or not wired), this setpoint is ignored.
170°F
(76.7°C)
50 to 190°F
(10 to 87.8°C)
Time of Day Setpoint
Used when an EnviraCOM thermostat is connected to the boiler and is in Sleep or
Away mode. When setback is “on” the time of day setback setpoint shifts the DHW
setpoint to lower the DHW temperature and to save energy while building is in a
reduced room temperature mode.
160°F
(71.1°C)
50 to 190°F
(10 to 87.8°C)
Difference Above
The boiler stops when the water temperature rises ‘Difference Above’ degrees above
the setpoint.
7°F
(-13.9°C)
3 to 29°F
(-16.1 to 1.7°C)
Difference Below
The boiler starts when the water temperature drops ‘Difference Below’ degrees below
the setpoint.
5°F
(-15°C)
3 to 29°F
(-16.1 to 1.7°C)
Domestic Low Fire Hold Time
“Low Fire Hold Time” is the number of minutes the control will wait at low fire
modulation rate before being released to modulate. After ignition and flame
stabilization periods the firing rate is held at low fire for “Low Fire Hold Time”. This
delay allows heat to travel out to the system and provide system feedback prior to the
control modulating firing rate.
10 seconds
0 to 1800 seconds
Response Speed
This parameter adjusts the Domestic Hot Water temperature controller Proportion
Integral Derivative (PID) values. Higher values cause a larger firing rate change for
each degree of temperature change. If set too high firing rate “overshoots” required
value, increases to high fire causing the temperature to exceed the “Difference
Above” setpoint and cycle the boiler unnecessarily. Lower values cause a smaller
firing rate change for each degree of temperature change. If set too low, the firing rate
response will be sluggish and temperature will wander away from setpoint. Refer to
Table 50 for PID values used by these selections.
3
1 to 5
96
X. Operation J. Parameter Adjustment (continued)
9. Domestic Hot Water Parameters, continued
Parameter and Description
DHW Modulation Sensor
Outlet Sensor: Boiler modulates for DHW demand in response to supply/outlet
sensor in boiler.
DHW Sensor:
Boiler modulates for DHW demand in response to DHW sensor at
boiler-side inlet to indirect water heater. Use for single boiler
servicing indirect water heater.
Factory Setting
Range / Choices
Outlet Sensor,
Outlet Sensor
DHW Sensor
Figure 61: Outdoor Reset Curve
97
X. Operation J. Parameter Adjustment (continued)
10. Outdoor Reset Parameters
Select
to access the following parameters.
Parameter and Description
Factory
Setting
Range /
Choices
Outdoor Reset Enable
If an outdoor sensor is installed and Outdoor Reset is Enabled, the boiler will automatically adjust
the heating set point temperature based on the outdoor reset curve in (see Figure 61). The
maximum set point is defined by the Central Heat Setpoint (default 180°F) when the outdoor
temperature is Min Outdoor Temp (default 32 F) or below. The minimum set point temperature
shown is 130°F when the outdoor temperature is 50°F or above. As the outdoor temperature falls
the supply water target temperature increases.
Disable
Do Not Calculate setpoint based on outdoor temperature
Enable
Calculate the temperature setpoint based on outdoor temperature using a reset
curve defined by Low Outdoor Temp, High Outdoor Temp, Low Boiler Water Temp,
Min Boiler Temp and Central Heat Setpoint and Boost Time parameters.
Enabled
Enable
Disable
Minimum Outdoor Temperature
Also called “Outdoor Design Temperature”. This parameter is the outdoor temperature used in the
heat loss calculation. It is typically set to the coldest outdoor temperature.
0°F
(-18°C)
-50 to 32°F
(-45.6 to 0°C)
Maximum Outdoor Temperature
Outdoor temperature at which the Low Water Temperature is supplied. This parameter is typically
set to the desired building temperature.
70°F
(21.1°C)
35 to 100°F
(1.7 to 37.8°C)
Low Water Temperature
Operating setpoint when the Maximum Outdoor Temperature is measured. If the occupied space
feels cool during warm outdoor conditions, the Low Water Temperature parameter should be
increased.
110°F
(43.3°C)
70 to 180°F
(21.1 to 82.2°C)
Minimum Boiler Water Temperature
Sets a low limit for the Reset setpoint. Set this parameter to the lowest supply water temperature
that will provide enough heat for the type radiation used to function properly. Always consider the
type of radiation when adjusting this parameter.
130°F
(54.4°C)
50 to 185°F
(10 to 85°C)
Central Heat Outdoor Reset Max Off Point
Maximum value the setpoint can reach due to boost function. Should be set to match Central Heat
Setpoint plus Differential Above.
190°F
(87.8°C)
50 to 190°F
(10 to 87.8°C)
Lead/Lag CH Outdoor Reset Max Off Point
Maximum value the setpoint can reach due to boost function. Should be set to match Central Heat
Setpoint plus Differential Above.
190°F
(87.8°C)
50 to 190°F
(10 to 87.8°C)
Boost Time
When the Central Heat Setpoint is decreased by Outdoor Reset settings, the Boost Time
parameter is used to increase the operating setpoint when the space heat demand is not satisfied
after the Boost Time setting is exceeded. When heat demand has been “on” continuously for
longer than the Boost Time parameter the operating setpoint is increased by 10°F (5.6°C). The
highest operating setpoint from Boost Time is current Central Heat Setpoint minus the Central
Heat “Diff Above” setting. A setting of 0 seconds disables this feature.
0 min.
0 to 30 min.
98
X. Operation J. Parameter Adjustment (continued)
11. Sequencer Master
NOTICE
Enable only one Sequencer Master boiler within
a group of networked boilers. Erratic behavior
will result if more than one Sequencer Master is
enabled.
Select
to access the following parameters.
Parameter and Description
Sequencer Master
The Sequencer Master Enable/Disable is used to “turn on” the multiple boiler leadlag control.
Factory
Setting
Range / Choices
Disabled
Enable
Disable
Boiler Piped
Boiler Piped
Primary Piped
One Boiler
One Boiler
Two Boiler
Boiler Start Delay
Slave boiler time delay after header temperature has dropped below Setpoint
minus Difference Below. Longer time delay prevents nuisance starts due to short
temperature swings.
5 min.
0.5 to 20 min.
Boiler Stop Delay
Slave boiler time delay after header temperature has risen above Setpoint plus
Difference Above. Longer time delay prevents nuisance stops due to short
temperature swings.
1 min.
0.5 to 5 min.
70%
25 to 100 %
24 hours
8 to 48 hours
Response Speed
This parameter adjusts the Central Heat temperature controller Proportion Integral
Derivative (PID) values. Higher values cause a larger firing rate change for each
degree of temperature change. If set too high firing rate “overshoots” required value,
increases to high fire causing the temperature to exceed the “Difference Above”
setpoint and cycle the boiler unnecessarily. Lower values cause a smaller firing
rate change for each degree of temperature change. If set too low, the firing rate
response will be sluggish and temperature will wander away from setpoint. Refer to
Table 11 for PID values used by these selections.
3
0 to 5
Stop All Boilers
When this temperature is reached, all networked boilers are stopped at once without
any time delay. This setting allows the sequencer to respond to rapid load increases.
195°F
(90.6°C)
Central Heat Setpoint to
195°F
(90.6°C)
Indirect Water Heater (IWH)
Boiler Piped
Sequencer to respond to an Isolated DHW demand that is piped to
a single boiler. The individual boiler goes on “Leave” from the
Sequencer Master and goes to DHW Service.
Primary Piped
The Sequence Master responds to the DHW Call For Heat. This
allows one or more boilers to provide heat to the IWH.
DHW Two Boiler Start
If enabled, the sequencer will immediately start two boilers for a DHW call for heat.
Used when DHW is the largest demand. Only relevant when “Primary Piped IWH” is
selected.
Base Load Rate
To maximize boiler efficiency, firing rate is limited to an adjustable value. Boilers are
kept at or below this firing rate as long as the boilers can handle the load. After last
available boiler has started, the modulation rate limit is released up to 100%.
Lead Rotation Time
Time boilers will act as the lead before switching the lead to another boiler in the
boiler to boiler network.
99
X. Operation J. Parameter Adjustment (continued)
12. Sequencer Slave
Select
to access the following parameters.
Parameter and Description
Factory Setting
Range / Choices
None
1 to 8
Normal
First
Normal
Last
Factory Setting
Range / Choices
20°F
(-6.7°C)
(Stepped
Modulation Recycle
Offset +6°F) to
30°F
10°F
(-12.2°C)
10°F to (Stepped
Modulation Start
Offset - 6 °F)
Preferred Supply High Limit
Adjustable high limit for supply temperature. Adjustable only up to control maximum
value.
Note: Included to allow installers and inspectors to test the limits.
210°F
(98.9°C)
60 to 210°F
(16 to 98.9°C)
Preferred Stack High Limit
Adjustable high limit for stack temperature. Adjustable only up to control maximum
value.
Note: Included to allow installers and inspectors to test the limits.
204°F
(95.6°C)
150 to 204°F
(65.6 to 95.6°C)
Boiler Address
Each boiler must be given a unique address. When Slave Selection Order is set to
Use Normal Order, the boiler address is used by the Sequence Master as the boiler
start order.
Slave Selection Order
First
Boiler will always be first to start.
Normal
Boiler start order follows boiler address number.
Last Boiler will always be last to start.
13. Limits
Select
to access the following parameters.
Parameter and Description
Stepped Modulation Start Offset
Reduces firing rate when supply, differential, or stack temperature is Stepped
Modulation Start Offset degrees below the high limit setting to help avoid lockouts.
For example, when the setting is 20°F, maximum modulation rate will begin to be
reduced when stack temperature is 20°F below the Stack High Limit and will be at
minimum modulation when stack temperature is 10°F below the limit.
Note: Feature is only active for supply temperature when Header Sensor is selected
as modulation sensor, when a boiler is a slave, or when a boiler is responding to a
remote demand (4-20mA or Modbus).
Stepped Modulation Recycle Offset
Recycles boiler when supply, differential, or stack temperature is Stepped Modulation
Recycle Offset degrees below the high limit setting to help avoid lockouts. For
example, when the setting is 10°F, the boiler will recycle when temperature is 10°F
below the limit.
Note: Feature is only active for supply temperature when Header Sensor is selected
as modulation sensor, when a boiler is a slave, or when a boiler is responding to a
remote demand (4-20mA or Modbus).
100
X. Operation J. Parameter Adjustment (continued)
14. Tune
Select
Select
to access the following parameters.
to access the following parameters.
Parameter and Description
Factory Setting
Range / Choices
Response Speed
Adjusts Central Heat temperature control Proportion Integral Derivative (PID)
values. A higher value causes a larger firing rate change per degree of requested
temperature change. If set too high, firing rate overshoots required value,
temperature exceeds Difference Above, and boiler cycles unnecessarily. A lower
value causes a smaller firing rate change per degree of requested temperature
change. If set too low, firing rate response will be sluggish and temperature will
wander away from setpoint. Refer to Table 50 for PID values used by these
selections.
3
1 to 5
Proportional Rate
Proportional gain value for Central Heat temperature control. A higher value yields
tighter, more active, PID control. Proportional Rate is the primary PID modulation
rate tuning adjustment and provides the immediate modulation rate response. Select
value based on desired initial response. If set too high, burner modulation rate can
oscillate.
26
0 to 400
Integral Rate
Integral gain value for Central Heat temperature control. A higher value yields faster
ramp rate. Integral is a secondary PID modulation rate tuning adjustment that ramps
the output over time (typically minutes). Based on the selected Local PID P, select the
corresponding (from above table) Integral value. Repeats per minute between 0.5 and
2.0 are typical. If set too high, burner modulation rate can oscillate.
9
0 to 400
101
X. Operation J. Parameter Adjustment (continued)
Select
to access the following parameters.
Parameter and Description
Factory Setting
Range / Choices
Response Speed
Adjusts Domestic Hot Water temperature control Proportion Integral Derivative
(PID) values. A higher value causes a larger firing rate change per degree of
requested temperature change. If set too high, firing rate overshoots required value,
temperature exceeds Difference Above, and boiler cycles unnecessarily. A lower
value causes a smaller firing rate change per degree of requested temperature
change. If set too low, firing rate response will be sluggish and temperature will
wander away from setpoint.
3
1 to 5
Proportional Rate
Proportional gain value for Domestic Hot Water temperature control. A higher
value yields tighter, more active, PID control. Proportional Rate is the primary PID
modulation rate tuning adjustment and provides the immediate modulation rate
response. Select value based on desired initial response. If set too high, burner
modulation rate can oscillate.
26
0 to 400
Integral Rate
Integral gain value for Domestic Hot Water temperature control. A higher value yields
faster ramp rate. Integral is a secondary PID modulation rate tuning adjustment that
ramps the output over time (typically minutes). Based on the selected Local PID
P, select the corresponding (from above table) Integral value. Repeats per minute
between 0.5 and 2.0 are typical. If set too high, burner modulation rate can oscillate.
9
0 to 400
Parameter and Description
Factory Setting
Range / Choices
Response Speed
Adjusts Sequence Master temperature control Proportion Integral Derivative (PID)
values when boiler is connected in boiler-to-boiler network. A higher value causes a
larger firing rate change per degree of requested temperature change. If set too high,
firing rate overshoots required value, temperature exceeds Difference Above, and
boiler cycles unnecessarily. A lower value causes a smaller firing rate change per
degree of requested temperature change. If set too low, firing rate response will be
sluggish and temperature will wander away from setpoint.
3
1 to 5
Proportional Rate
Proportional gain value for Sequencer Master temperature control. A higher value
yields tighter, more active, PID control. Proportional Rate is the primary PID
modulation rate tuning adjustment and provides the immediate modulation rate
response. Select value based on desired initial response. If set too high, burner
modulation rate can oscillate.
22
0 to 400
Integral Rate
Integral gain value for Sequencer Master temperature control. A higher value yields
faster ramp rate. Integral is a secondary PID modulation rate tuning adjustment that
ramps the output over time (typically minutes). Based on the selected Local PID
P, select the corresponding (from above table) Integral value. Repeats per minute
between 0.5 and 2.0 are typical. If set too high, burner modulation rate can oscillate.
7
0 to 400
Select
102
to access the following parameters.
X. Operation J. Parameter Adjustment (continued)
Select
to access the following parameters.
Parameter and Description
Factory Setting
Range / Choices
Fan Speed-Up Ramp
Maximum fan ramp rate when fan speed is increasing.
0
0 to 12000 rpm
Fan Speed-Down Ramp
Maximum fan ramp rate when fan speed is decreasing.
0
0 to 12000 rpm
Fan Gain Up
Fan gain when fan speed is increasing.
15
1 to 100
Fan Gain Down
Fan gain when fan speed is decreasing.
5
1 to 100
CH Slow Start Enable/Disable
Enables or disables the slow start limit function for Central Heat and Sequence
Master demand sources. Uses the CH Low Fire Hold Rate parameter as the starting
point for the slow start.
Disabled
Enable
Disable
DHW Slow Start Enable/Disable
Enables or disables the slow start limit function for DHW demand source. Uses the
DHW Low Fire Hold Rate parameter as the starting point for the slow start.
Disabled
Enable
Disable
20°F
(11°C)
0 to 180°F
(0 to 82.2°C)
200 % / min.
0 to 1000 rpm
Factory Setting
Range / Choices
On
On
Off
Slow Start Degrees
If Slow Start is enabled and supply temperature is less than setpoint minus Slow Start
Degrees, then slow start rate limiting is effective. Slow start rate limiting has no effect
when supply temperature is greater than setpoint minus Slow Start Degrees.
Slow Start Ramp
When slow start rate limiting is in effect, the modulation rate will increase no more
than the amount per minute given by this parameter. Although provided as a perminute value, the Control will calculate and apply this as a stepped function using
step duration of 10 seconds.
Select
to access the following parameters.
Parameter and Description
Sequencer On/Off
Turns control internal sequencer on or off.
103
X. Operation (continued)
K. USB Thumb Drive Parameter Transfer
Load Parameters from USB
A USB port is provided on left side of boiler
display panel. When used with a thumb drive,
this port can be used to save parameters from
boiler to thumb drive and load parameters from
thumb drive to boiler. This feature allows for easy
transfer of boiler parameters from one boiler to
another. Refer to Table 51 for a list of parameters
transferrable by USB port.
•
•
USB Thumb Drive Requirements
The thumb drive must be formatted as a FAT32
for use with the display. In order to check the
format of a USB thumb drive, follow these
instructions:
• Plug the USB drive into a computer
• Ensure that the USB drive does not have
anything currently saved on it.
• Go to My Computer (Select Start >> Computer)
• Right click on Removable Disk and select
Properties
• Under the General tab, confirm File system:
FAT32
• If it does not say FAT32, close window, return to
My Computer
• Right Click on Removable Disk and select
Format
• Select File system = FAT32
• Select Start and then select OK to format the
USB Thumb Drive.
• The USB Thumb Drive is now FAT32 format
Save Parameters to USB
Saves the current parameter settings of the
boiler, including the contact information of
the contractor, Service Company, and sales
representative, to a USB Drive. Follow these
steps to save parameters.
• Plug USB thumb drive into boiler USB port
• Select Main Menu >> Archives >> Save
Parameters to USB
• Confirm or Save Parameters
• Once procedure is complete the display saves
two files: a parameter file called Recipe.csv, and
a contact information file called Recipe32.csv.
Select My Computer >> Removable Disk >>
HMI > HMI000 to access these files.
104
•
•
Loads the current saved parameter settings from
a USB drive. Parameter files must be stored
in My Computer >> Removable Disk >> HMI
>> HMI000. Two files should be stored: a
parameter file called Recipe.csv, and a contact
information file called Recipe32.csv. Follow
these steps to load parameters.
Plug USB thumb drive into boiler USB port
Select Main Menu >> Archives >> Load
Parameters from USB
Confirm or Cancel Load of Parameters.
Confirm or Cancel Load of Contact Information.
Table 51: Parameters Summary
Parameter
Security
USB
Load/Save
SYSTEM
Temperature Units
Basic
X
Outdoor Sensor Source
Basic
X
Outdoor Sensor Calibration
Basic
X
Anti short Cycle Time
Basic
X
CH Frost Protection
Basic
X
CH Frost Protection Setpoint
Basic
X
Installer Password
Factory
X
Warm Weather Shutdown Enable
Basic
X
Warm Weather Shutdown Setpoint
Basic
X
System Date
Basic
System Time
Basic
Auto Jump To Home Page
Basic
MODULATION
Boiler Type
Factory
CH Max Modulation Rate
Factory
DHW Max Modulation Rate
Factory
Minimum Modulation Rate
Factory
Lightoff Rate
Factory
OPERATION
Auto/Manual
Supervisor
Rate
Supervisor
X
X. Operation K. USB Thumb Drive Parameter Transfer (continued)
Table 51: Parameters Summary (continued)
Table 51: Parameters Summary (continued)
Security
USB
Load/Save
System Pump
Supervisor
X
Boiler Pump
Supervisor
X
DHW Pump
Supervisor
X
CH pump overrun time
Supervisor
X
DHW pump overrun time
Supervisor
X
Boiler pump overrun time
Supervisor
X
Pump exercise interval
Supervisor
X
Preferred Stack Limit Setpoint
Factory
X
Pump exercise time
Supervisor
X
Preferred Outlet Limit Setpoint
Factory
X
CH Setpoint
Basic
X
Modulation Source
Supervisor
CH TOD Setback Setpoint
Basic
X
CH Demand Switch
Supervisor
CH Difference Above
Basic
X
LL Demand Switch
Supervisor
CH Difference Below
Basic
X
4mA Water Temp
Supervisor
CH Response Speed
Supervisor
X
Lead Lag Setpoint Source
Supervisor
CH Modulation Sensor
Supervisor
X
Central Heat Setpoint Source
Supervisor
Central Heat Low Fire Hold Time
Supervisor
X
20mA Water Temp
Supervisor
Analog Input Hysteresis
Supervisor
Parameter
PUMPS
CENTRAL HEAT
Parameter
Security
USB
Load/Save
SEQUENCER SLAVE
Slave Selection Order
Supervisor
Boiler Address
Supervisor
LIMITS
Stepped Modulation Start Offset
Factory
X
Stepped Modulation Recycle
Offset
Factory
X
EMS REMOTE DEMAND
DOMESTIC HOT WATER
DHW Priority Time
Basic
X
DHW Setpoint
Basic
X
Fan speed - up ramp
Supervisor
X
DHW TOD Setback Setpoint
Basic
X
Fan slow - down ramp
Supervisor
X
DHW Difference Below
Basic
X
Fan gain up
Factory
X
DHW Difference Above
Basic
X
Fan gain down
Factory
X
DHW Response Speed
Supervisor
X
CH slow start enable/disable
Supervisor
X
Domestic Low Fire Hold Time
Supervisor
X
DHW slow start enable/disable
Supervisor
X
DHW Modulation
Supervisor
X
Slow start ramp
Supervisor
X
Slow start degrees
Supervisor
X
Outdoor Reset Enable/Disable
Basic
X
Minimum Outdoor Temperature
Basic
X
Maximum Outdoor Temperature
Basic
X
Low Water Temperature
Basic
X
Minimum Boiler Water Temperature
Basic
X
Boost Time
Basic
X
Central Heat ODR Max Off Point
Basic
X
Lead Lag CH ODR Max Off Point
Basic
X
OUTDOOR RESET
FAN TUNE
SEQUENCER MASTER
Master Enable/Disable
Supervisor
Base Load Common Rate
Supervisor
Indirect Water Heater
Supervisor
Boiler Start Delay
Supervisor
DHW Two Boiler Start
Supervisor
Stop All Boilers
Boiler Stop Delay
Lead Rotation Time
Response Speed
Basic
Supervisor
Basic
Supervisor
105
X. Operation (continued)
L. Multiple Boiler Control Sequencer
1. Setup
NOTICE
Enable only one Sequencer Master boiler within a group of networked boilers. Erratic behavior will
result if more than one Sequencer Master is enabled. Assign all boilers a unique address. Undesirable
simultaneous operation occurs when two boilers’ addresses are the same.
Complete steps shown in Table 52 to set up a multiple boiler system. Refer to J. Parameter Adjustment, parts 11 and 12.
Table 52: Multiple Boiler Setup Procedure
Step
Description
Comments
1
Wire the header
sensor
Wire a header sensor to Header Sensor terminals of the boiler to be used as the Sequencer
Master. See Figures 32 and 33 for header sensor installation detail.
NOTE: This step cannot be skipped. The Sequencer Master cannot be enabled unless a Header
Sensor is installed.
2
Install Ethernet
cables between
boilers
See Figure 44. Use standard Ethernet type cables to make connection between boilers.
Alternatively, terminal screws A, B, and C labeled Boiler-to-Boiler may be used.
3
Set unique boiler
addresses
Assign all boilers a unique Boiler Address using any number from 1 through 8. Select Main
Menu >> Adjust >> Sequencer Slave >> Boiler Address.
4
Enable one
Sequencer Master
boiler
5
Confirm
communication
Enable the Sequencer Master on the boiler with header sensor installed. Enable only one boiler
as the Sequencer Master. Select Main Menu >> Adjust >> Sequencer Master >> Enable.
Power down all boilers. Power up Sequencer Master boiler first. On the Sequencer Master
boiler, select Status. The Sequencer display should show boiler addresses of communicating
boilers. If a boiler is not shown, check Ethernet cable connections and confirm all boilers have
unique addresses.
2. Features
Sequencer Master
A single boiler is selected to be the permanent Sequencer Master (i.e. does not rotate). The call for heat, outdoor and
header sensors, and common pumps are wired to the Sequencer Master boiler.
Lead/Slave Sequencing
The Sequencer Master is independent of the lead boiler. One boiler is a lead boiler and the remaining networked boilers
are slaves. When demand is increasing, the lead boiler is the first to start and the slave boilers are started in sequential
order (1, 2, 3,…) until the demand is satisfied. When demand is decreasing, the boilers are stopped in reverse order with
the lead boiler stopped last (…, 3, 2, 1). To equalize the run time, the sequencer automatically rotates the lead boiler after
24 hours of run time.
Sequence of Operation
Multiple boiler sequence of operation is illustrated in Figure 62. After there is a demand, both header water temperature
and boiler firing rate percent are used to start and stop networked boilers. The control starts and stops boilers when water
temperature is outside Difference Above and Difference Below settings. To minimize temperature deviations, the control
adjusts the number of boilers running based on the firing rate. This combination allows the boilers to anticipate slow load
changes before they disrupt water temperature, yet still respond quickly to sudden load changes. These special sequencer
features help reduce energy wasting system temperature swings and the resulting unnecessary boiler cycling.
1
2
3
4
5
106
Lead Boiler Start - Temperature below setpoint by more than Difference Below
Temperature Based Lag Boiler Start - Temperature below setpoint by more than Difference Below for longer than
Boiler Start Delay (adjustable parameter)
Modulation % Based Lag Boiler Start – Firing rate has been at maximum for longer than 20 min.
Lag Boiler Stop – Firing rate has been at minimum for longer than 20 min. Additionally, lag boilers are stopped when
water temperature is above setpoint by more than Difference Above for longer than Boiler Stop Delay.
Lead Boiler Stop – Lead boiler fires until water temperature is above setpoint more than Difference Above for longer
than Boiler Stop Delay.
Setpoint
SYSTEM
TEMPERATURE
X. Operation L. Multiple Boiler Control Sequencer (continued)
185
180
175
5
2
1
BOILER
FIRING RATE
100
Base Load
Rate
Default 40%
Range
(25 – 100%)
40
2
3
4
4
5
PLANT LOAD
(# BOILERS REQURED)
0
3
2
1
0
Start
Lead Boiler
Fast
Load
Change
Slow
Load
Change
Start
1st Lag
Start
2nd Lag
Stop
2nd Lag
Stop
1st Lag
Stop
Lead Boiler
Figure 62: Multiple Boiler Sequence Diagram
(3 boiler system shown, typical for up to 8 boilers)
Optimized Boiler Modulation
Boiler firing rate is managed to increase smoothly
as boilers are started. For example, when a second
boiler is started the initial firing rate is 100%/2
or 50%, when the third boiler is started the firing
rate starts at 200%/3 or 66%. After the initial
start, the Sequencer Master develops a unison
firing rate demand based on its setpoint and header
temperature.
Base Load Rate
During low loads, the Sequencer Master limits firing
rates to a Base Load Rate to ensure modulating
condensing boiler peak operating efficiency. Lower
firing rates boost efficiency by helping increase the
amount of flue gas water vapor condensation. The
control maintains a Base Load Rate until the last lag
boiler is started. At this point, the Base Load Rate is
released to allow boilers to modulate as required to
meet heat load.
Customized Sequences
Normally, boilers are started and stopped in
numerical order. However, custom sequences
may be established to optimize the heat delivery.
For example, in order to minimize boiler cycling,
a large boiler may be selected to run first during
winter months and then selected to run last for the
remainder of the year.
Multiple Demands
The Sequencer Master responds to Central Heat,
DHW and frost protection demands similar to
a stand-alone boiler. For example, when DHW
Priority Time is nonzero and DHW priority is
active, the Sequencer Master uses DHW setpoint,
Differential Above, Differential Below and pump
settings. However, the Sequencer Master always
uses the header sensor and does not use the DHW
sensor.
DHW Two boiler Start
When the DHW Pump parameter is set to DHW
Pump: Primary Loop Piped IWH and the Sequencer
Master DHW Two Boiler Start parameter is set to
Two Boiler, two boilers are started without delay
in response to DHW demand. This feature allows
rapid recovery of large indirect water heaters
(IWH’s) and multiple IWH’s.
Shared or Isolated DHW Demand
When the DHW Pump parameter is set to Primary
Loop Piped IWH, the Sequence Master sequences
all required boilers to satisfy the DHW demand.
When the DHW Pump parameter is set to Boiler
Piped IWH, only the individual slave boiler, with
wired DHW Demand or DHW Sensor and pump,
fires to satisfy DHW demand.
107
X. Operation L. Multiple Boiler Control Sequencer (continued)
Backup Header Sensor
If the header sensor fails, the Sequencer Master uses
the lead boiler’s supply sensor to control firing rate.
This feature allows continued coordinated sequencer
control even after a header sensor failure.
Improved Availability
The following features help improve the heat
availability:
• Slave Boiler Rate Adjustment – Each slave
boiler continues to monitor supply, return and
flue gas temperatures and modifies the Sequencer
Master firing rate demand to help avoid
individual boiler faults, minimize boiler cycling
and efficiently provide heat to the building.
• Slave Boiler Status Monitoring – Sequencer
Master monitors slave boiler lockout status and
automatically skips over disabled boilers when
starting a new slave boiler.
• Stand Alone Operation Upon Master Failure
– Individual boilers are configured to continue
to operate in the event the Sequencer Master
control is powered down, disabled or boiler-toboiler communication is lost. The following are
design considerations for backup “Stand Alone”
operation. Once the Sequence Master is restored
to operation the individual boilers automatically
resume their position as sequencer slaves.
o Enable/Disable – Upon loss of Sequencer
Master, each boiler will automatically
begin local control. This means it will
operate only if it has a call for heat. For
this reason slave boilers should have
108
their Enable/Disable terminals jumpered
so each boiler has demand if Sequencer
Master is lost.
o Modulation – Once running, each slave
boiler will use its selected central heat
modulation sensor and setpoint to
produce heat for the building. To allow
continued header water temperature
control, slave boilers may have separate
header sensors wired with the CH
Modulation Sensor parameter selected as
Header Sensor.
o Pumping – Consideration must be given
to how the system pump is powered. If
the Sequencer Master enabled boiler
is powered down, how will the system
pump be operated? It may be required to
wire the system pump to multiple boilers.
X. Operation (continued)
M. Energy Management System (EMS) Interface
The control system has a fully featured ability to interface with an Energy Management System (EMS). The control system
allows remote control and monitoring via RS485 Modbus or through direct wiring. The following sections outline setup of
the EMS interface and adjustable EMS interface parameters. Select Main Menu >> EMS to access EMS parameters.
1. Setup
Complete steps shown in Table 53 to set up a multiple boiler system with EMS interface.
Table 53: Energy Management System Setup Procedure
Step
Description
Comments
See Figure 44. Use standard Ethernet type cables to make connection between boilers. Alternatively,
Install Ethernet cables terminal screws A, B, and C labeled Boiler-to-Boiler may be used.
between boilers
NOTE: The same Ethernet cable that connects the Boiler-To-Boiler Sequence Master also connects the
EMS Modbus signals.
1
Enable EMS
communication
2
Select Main Menu >> EMS >> Modbus Setup >> EMS Enable/Disable >> Enable.
SEE PAGE 110 BEFORE PROCEEDING
Set unique Modbus
Program COM2 only
addresses
“Comm HMI Station” The EMS Modbus address may be independent to the Boiler number or boiler address. Select Main
Menu >> EMS >> Modbus Setup >> EMS Modbus Parameters. Follow on screen instructions.
NOTE: Each boiler must have a unique Comm HMI Station address.
3
Communication parameters are adjustable. Select Main Menu >> EMS >> Modbus Setup >> EMS
Adjust communication
Modbus Parameters. Follow on screen instructions.
parameters
NOTE: Baud Rate and Parity must match the EMS settings for communication to be established.
4
Confirm
communication
5
The display provides a list of all EMS signals. Select Main Menu >> EMS >> Points List. Use the list to
verify signals sent and received from the EMS.
2. Remote Demand Parameters
Select
to access the following parameters.
Factory
Setting
Range / Choices
Local
Local,
4-20 mA,
Modbus
Local
Local,
4-20 mA,
Modbus
Local
Local,
Modbus
Local
Local,
Modbus
4-20 mA Water Temp
Sets the Central Heat Setpoint temperature corresponding to 4 mA.
130°F
(54.4°C)
50°F (10°C) Central Heat Setpoint
20 mA Water Temp
Sets the Central Heat Setpoint temperature corresponding to 20 mA.
180°F
(82.2°C)
50°F (10°C) Central Heat Setpoint
Parameter and Description
Modulation Source
The boiler can modulate (vary boiler heat input) based on local or remote (4-20 mA or
Modbus) signals. Modulation begins after the start sequence finishes and the boiler is
released to modulate. Modulation Source has the following selections:
Local Local setpoint and control is used to create firing rate.
4-20mA Input wired to Remote 4-20 mA terminals is used as modulation rate.
Modbus Modbus signal is used as modulation rate.
Central Heat Setpoint Source & Lead Lag Setpoint Source
The setpoint may be based on local (customer entered value or outdoor reset) or remote
(4-20mA or Modbus) signals. Setpoint Source has the following selections:
Local Local setpoint and control is used to create firing rate.
4-20mA Input wired to Remote 4-20 mA terminals is used as modulation rate.
Modbus Modbus signal is used as modulation rate.
CH Demand Switch
The Central Heat demand (Enable Disable) can be directly wired to the boiler or provided by
the Modbus interface. Ignored when boiler is controlled by sequencer.
Local Enable Disable terminals provide demand.
Modbus Modbus signal provides demand.
LL Demand Switch
The Sequencer Master’s demand (Enable Disable) can be directly wired to the boiler or
provided by the Modbus interface. Used only on Sequencer Master boiler.
Local Enable Disable terminals provide demand
Modbus Modbus signal provides demand.
109
X. Operation M. Energy Management System (EMS) Interface (continued)
3. Modbus Setup Parameters
Select
to bring up the following sub-menu.
Select
to view and/or adjust COM port parameters as needed to communicate with an EMS. Follow on
screen instructions. COM 1 is used for communication between touch screen display and the boiler control and does not require
adjustment. COM 2 is used for communication between an EMS and the boiler control and may require adjustment to suit the
EMS.
NOTICE
Do NOT change COM 1 settings. Loss of communication between control and display could result. Read
all on screen instructions before entering System Menu.
Select System Menu >> System Setting >> COM Port to access the following parameters. To exit System Menu, cycle power or
select open blue area of screen.
COM Port
COM Port Configure For
Control: communication between boiler display and
boiler control
EMS:
communication between EMS and boiler control
Port Type (non-adjustable)
Special Notes
COM Mode
Baud Rate
Stop Bits
Data Bits
Parity Bits
Comm. Delay (ms)
Comm. Timeout (ms)
Comm. Retry Times
Comm. HMI Station
This is Modbus Slave Address.
Baud Rate Fine Tuning
PLC Default Station
This is address Modbus Master is reading.
110
COM 1
COM 2
Control
EMS
Modbus Master
NOTICE: Do not change any of these settings.
Loss of communication to control could result.
RS 485
38400
1 bit
8 bit
None
10 ms
1000 ms
2
0
(not used)
0
Modbus Slave
Adjust these settings
to suit the EMS
RS 485
38400
1 bit
8 bit
None
10 ms
1000 ms
2
1
1 (not used)
1
0
X. Operation M. Energy Management System (EMS) Interface (continued)
4. Modbus Register List
A list of available Modbus registers and descriptions is stored in the display and provided in Table 54. To access
Select
to access the list of available Modbus registers.
Table 54. Modbus Register List
ENABLE/DISABLE
Modbus
Register
Protocol
Name
Description
Read (R) /
Write (W)
Central Heat
Enable/Disable
Central Heat Enable/Disable
0 = Disable
1 = Enable
When this register is not written every “Modbus Command Time Out” parameter
seconds (default 30 seconds), CH Modbus Stat is reverted to 0 no demand.
W
400563
LLCH Modbus Stat
LL CH Modbus STAT
0 = no demand
1 = demand
When this register is not written every “Modbus Command Time Out” parameter
seconds (default 30 seconds), CH Modbus Stat is reverted to 0 no demand.
W
400203
Burner on/off
Burner On/Off burner.
1 = on
0 = off
R
R
400577
400006
Demand source
0 = Unknown
1 = No source demand
2 = Central heat
3 = Domestic hot water
4 = Lead Lag slave
5 = Lead Lag master
6 = Central heat frost protection
7 = Domestic hot water frost protection
8 = No demand due to burner switch turned off
9 = Domestic hot water storage
11 = Warm weather shutdown
400066
CH heat demand
0=Off,
1=On
R
400083
DHW heat demand
0=Off,
1=On
R
400123
Low Temperature
Loop heat demand
0=Off,
1=On
R
SETPOINTS
410579
Use this register to change the boiler setpoint.
When this register is not written every “Modbus Command Time Out” parameter
CH Modbus Setpoint
seconds (default 30 seconds), setpoint reverts to local setpoint
valid range 60 F to 190 F
W
Use this register to change the multiple boiler Sequencer setpoint.
When this register is not written every “Modbus Command Time Out” parameter
seconds (default 30 seconds), setpoint reverts to local setpoint
valid range 60 F to 190 F
W
410562
CH Sequencer
Modbus Setpoint
410211
CH setpoint
Status of local setpoint
R
410453
DHW setpoint
Status of local setpoint
R
410546
Lead Lag setpoint
Status of local setpoint
R
410212
CH TOD setpoint
Status of local setpoint
R
111
X. Operation M. Energy Management System (EMS) Interface (continued)
Table 54. Modbus Register List (continued)
SETPOINTS
Modbus
Register
Protocol
Name
Description
Read (R) /
Write (W)
410065
CH setpoint source
0=Unknown,
1=Normal setpoint,
2=TOD setpoint,
3=Outdoor reset,
4=Remote control (4-20mA ),
7=Outdoor reset time of day
410016
Active CH setpoint
-40 F (-40°C) to 266 F (130°C)
Setpoint determined by CH setpoint source (register 65).
R
0=Unknown,
1=Normal setpoint,
2=TOD setpoint,
5=DHW tap setpoint,
6=DHW preheat setpoint
R
-40 F (-40°C) to 266 F (130°C) Setpoint determined by DHW setpoint source
(register 81).
R
R
410081
DHW setpoint
source
410017
Active DHW setpoint
R
410162
Lead Lag master
setpoint source
0=Unknown,
1=CH setpoint,
2=CH TOD setpoint,
3=Outdoor reset,
4=Remote control (4-20mA ),
5=DHW setpoint,
6=DHW TOD setpoint,
7=Outdoor reset time of day,
8=Mix setpoint
410018
Active LL setpoint
-40 F (-40°C) to 266 F (130°C)
Setpoint determined by LL setpoint source (register 162).
R
410643
Low Temperature
setpoint
Setpoint entered on the local user interface.
valid range 79 F (26.1 C) to 191 F (88.3 C)
R
410121
Low Temperature
setpoint source
0=Unknown,
1=Normal setpoint,
2=TOD setpoint,
3=Outdoor reset,
4=Remote control,
7=Outdoor reset time of day,
9=Outdoor boost
R
410024
Active Low
Temperature
setpoint
-40 F (-40°C) to 266 F (130°C) Setpoint determined by Low Temp setpoint source
(register 121).
R
112
X. Operation M. Energy Management System (EMS) Interface (continued)
Table 54: Modbus Register List (continued)
TEMPERATURE SENSORS
Modbus
Register
Protocol
Name
410007
Supply sensor
-40 F (-40°C) to 266 F (130°C)
R
Description
Read (R) /
Write (W)
410011
Return sensor
-40 F (-40°C) to 266 F (130°C)
R
410013
Header sensor
-40 F (-40°C) to 266 F (130°C)
R
410014
Stack sensor
-40 F (-40°C) to 266 F (130°C)
R
410170
Outdoor sensor
-40 F (-40°C) to 266 F (130°C)
R
4 - 20 mA sensor
mA value for S2 (J8-6) parameter selectable as
(remote set point) & (remote modulation)
R
Modbus Outdoor
Temp
Building Automation may send the controller the outdoor air temperature. Use
this register to change the outdoor temperature. When this register is not written
every “Modbus Command Time Out” parameter seconds (default 30 seconds),
temperature is set to bad data quality and outdoor air reset is set back to local
setpoint.
valid range -40 F to 302 F
W
400015
410817
BURNER
Use this register to drive individual boiler firing rates. This register is used when
firing rate control is performed by an external building automation system. Firing
rate reverts to local control when register is not written every “Modbus Command
Time Out” parameter seconds (default 30 seconds),
Range is 0 to 200 % provides 0-100% firing rate.
W
400581
CH Modbus Rate
400008
Fan Speed
Measured
Speed of the combustion air blower in rpm
R
400009
Fan Speed
Commanded
Speed of the combustion air blower in rpm
R
400010
Flame signal
0.01V or 0.01μA precision (0.00-50.00V)
R
0Initiate
1
Standby Delay
2
Standby
3
Safe Startup
4
Prepurge - Drive to Purge Rate
5
Prepurge – Measured Purge Time
6
Prepurge – Drive to Lightoff Rate
7
Preignition Test
8
Preignition Time
9
Pilot Flame Establishing Period
10
Main Flame Establishing Period
11
Direct Burner Ignition
12
Run
13Postpurge
14Lockout
R
400033
Burner control state
113
X. Operation M. Energy Management System (EMS) Interface (continued)
Table 54: Modbus Register List (continued)
TROUBLESHOOTING
Modbus
Register
410034
410040
Protocol
Name
Lockout code
Hold code
Description
Read (R) /
Write (W)
Reasons for burner lockout
0
No lockout,
4
Supply high limit
5
DHW high limit
6
Stack High limit
12
Flame detected out of sequence
18
Lightoff rate proving failed
19
Purge rate proving failed
20
Invalid Safety Parameters
21
Invalid Modulation Parameter
22
Safety data verification needed
23
24VAC voltage low/high
24
Fuel Valve Error
25
Hardware Fault
26
Internal Fault
27
Ignition Failure
R
Reason for burner hold
0
None
1
Anti short cycle
2
Boiler Safety Limit Open
3
Boiler Safety Limit Open, (ILK Off)
7
Return sensor fault
8
Supply sensor fault
9
DHW sensor fault
10
Stack sensor fault
11
Ignition failure
13
Flame rod shorted to ground
14
Delta T inlet/outlet high
15
Return temp higher than supply
16
Supply temp has risen too quickly
17
Fan speed not proved
23
24VAC voltage low/high
25
Hardware Fault
27
Ignition Failure
R
STATISTICS
This parameter sets the amount of time the control will wait for input from the
Building Automation System (BAS). If the BAS does not write to the following
register within the “Modbus Command timeout” seconds the following inputs are
considered invalid:
400763
Modbus command
timeout
CH Modbus Stat,
CH Modbus Setpoint,
CH Sequencer Modbus Setpoint
CH Modbus Rate
range 30 – 120 Default 30 seconds
Other R/W registers should only be written when a value is needed to be
changed. Only the above listed registers are stored in non-volatile registers.
114
R/W
X. Operation M. Energy Management System (EMS) Interface (continued)
Table 54: Modbus Register List (continued)
PUMP STATUS
Modbus
Register
Protocol
Name
Read (R) /
Write (W)
400096
CH pump status
See Table 55.
R
400100
DHW pump status
See Table 55.
R
400108
Boiler pump status
See Table 55.
R
0-999,999 (U32)
R/W
Hours (U32)
R/W
Description
400128 - 400129
Burner cycle count
400130 - 400131
Burner run time
400132 - 400133
System pump cycle count
0-999,999 (U32)
R/W
400134 - 400135
DHW pump cycle count
0-999,999 (U32)
R/W
400138 - 400139
Boiler pump cycle count
0-999,999 (U32)
R/W
Table 55: Pump Status Codes
Status
Description
Status
Description
92
Forced On from manual pump control
110
On from local Mix demand
93
Forced On due to Outlet high limit is active
111
On from Lead Lag Mix demand
94
Forced On from burner demand
112
On from local Central Heat service
95
Forced On due to Lead Lag slave has demand
113
On from Lead Lag Central Heat service
96
Forced Off from local DHW priority service
114
On from local DHW service
97
Forced Off from Lead Lag DHW priority service
115
On from Lead Lag DHW service
98
Forced Off from Central Heat anticondensation
116
On from local Mix service
99
Forced Off from DHW anti-condensation
117
On from Lead Lag Mix service
100
Forced Off due to DHW high limit is active
118
On from Lead Lag auxiliary pump X
101
Forced Off from EnviraCOM DHW priority
service
119
On from Lead Lag auxiliary pump Y
102
On due to local CH frost protection is active
120
On from Lead Lag auxiliary pump Z
103
On due to Lead Lag CH frost protection is
active
121
On, but inhibited by pump start delay
104
On due to local DHW frost protection is active
122
On from pump override
105
On due to Lead Lag DHW frost protection is
active
123
Off, not needed
106
On from local Central Heat demand
124
On from burner demand
107
On from Lead Lag Central Heat demand
125
On from exercise
108
On from local DHW demand
126
On from local Lead Lag service
109
On from Lead Lag DHW demand
127
On from local Lead Lag pump demand
115
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. When disturbed as a
result of servicing or repair, these substances become airborne and, if
inhaled, may be hazardous to your health.
AVOID Breathing Fiber Particulates and Dust
Precautionary Measures:
Do not remove or replace RCF parts or attempt any service or repair work
involving RCF without wearing the following protective gear:
1. A National Institute for Occupational Safety and Health (NIOSH)
approved respirator
2. Long sleeved, loose fitting clothing
3. Gloves
4. Eye Protection
•
Take steps to assure adequate ventilation.
•
Wash all exposed body areas gently with soap and water after contact.
•
Wash work clothes separately from other laundry and rinse washing
machine after use to avoid contaminating other clothes.
•
Discard used RCF components by sealing in an airtight plastic bag. RCF
and crystalline silica are not classified as hazardous wastes in the United
States and Canada.
First Aid Procedures:
116
•
If contact with eyes: Flush with water for at least 15 minutes. Seek
immediate medical attention if irritation persists.
•
If contact with skin: Wash affected area gently with soap and water.
Seek immediate medical attention if irritation persists.
•
If breathing difficulty develops: Leave the area and move to a
location with clean fresh air. Seek immediate medical attention if
breathing difficulties persist.
•
Ingestion: Do not induce vomiting. Drink plenty of water. Seek
immediate medical attention.
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. Installation and service must be performed only by an experienced,
skilled, and knowledgeable installer or service agency
This boiler must be properly vented.
This boiler needs fresh air for safe operation and must be installed so there are provisions for
adequate combustion and ventilation air.
Asphyxiation Hazard. The interior of the venting system must be inspected and cleaned before the
start of the heating season and should be inspected periodically throughout the heating season for
any obstructions. A clean and unobstructed venting system is necessary to allow noxious fumes
that could cause injury or loss of life to vent safely and will contribute toward maintaining the boiler’s
efficiency.
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 this manual for details.
This boiler is supplied with safety devices which may cause the boiler to shut down and not re-start
without service. If damage due to frozen pipes is a possibility, the heating system should not be left
unattended in cold weather; or appropriate safeguards and alarms should be installed on the heating
system to prevent damage if the boiler is inoperative.
Burn Hazard. This boiler contains very hot water under high pressure. Do not unscrew any pipe
fittings nor attempt to disconnect any components of this boiler without positively assuring the water
is cool and has no pressure. Always wear protective clothing and equipment when installing, starting
up or servicing this boiler to prevent scald injuries. Do not rely on the pressure and temperature
gauges to determine the temperature and pressure of the boiler. This boiler contains components
which become very hot when the boiler is operating. Do not touch any components unless they are
cool.
Respiratory Hazard. Boiler materials of construction, products of combustion and the fuel contain
alumina, silica, heavy metals, carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or
harmful substances which can cause death or serious injury and which are known to the state of
California to cause cancer, birth defects and other reproductive harm. Always use proper safety
clothing, respirators and equipment when servicing or working nearby the appliance.
Failure to follow all instructions in the proper order can cause personal injury or death. Read all
instructions, including all those contained in component manufacturers manuals which are provided
with the boiler before installing, starting up, operating, maintaining or servicing.
All cover plates, enclosures and guards must be in place at all times.
NOTICE
This boiler has a limited warranty, a copy of which is included with this boiler. It is the responsibility of
the installing contractor to see that all controls are correctly installed and are operating properly when the
installation is complete.
117
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.
Do not attempt any service work if gas is present in the air in the vicinity of the boiler. Never modify,
remove or tamper with any control device.
WARNING
This boiler must only be serviced and repaired by skilled and experienced service technicians.
If any controls are replaced, they must be replaced with identical models.
Read, understand and follow all the instructions and warnings contained in all the sections of this
manual.
If any electrical wires are disconnected during service, clearly label the wires and assure that the wires
are reconnected properly.
Never jump out or bypass any safety or operating control or component of this boiler.
Read, understand and follow all the instructions and warnings contained in ALL of the component
instruction manuals.
Assure that all safety and operating controls and components are operating properly before placing
the boiler back in service.
Annually inspect all vent gaskets and replace any exhibiting damage or deterioration.
NOTICE
Warranty does not cover boiler damage or
malfunction if the following steps are not
performed at the intervals specified.
A.Continuously:
1. Keep the area around the boiler free from
combustible materials, gasoline and other flammable
vapors and liquids.
2. Keep the area around the combustion air inlet
terminal free from contaminates.
3. Keep the boiler room ventilation openings open and
unobstructed.
B. Monthly Inspections:
1. Inspect the vent piping and outside air intake piping
to verify they are open, unobstructed and free from
leakage or deterioration. Check screens in vent and
air intake terminations to verify they are clean and
free of debris. Call the service technician to make
repairs if needed.
2. Inspect the condensate drain system to verify it is
leak tight, open and unobstructed. Call the service
technician if the condensate drain system requires
maintenance.
118
3. Inspect the water and gas lines to verify they are
free from leaks. Call the service technician to make
repairs if required.
NOTICE
Water leaks can cause severe corrosion damage
to the boiler or other system components.
Immediately repair any leaks found.
C. Annual Inspections and Service: In addition
to the inspections listed above the following should be
performed by a service technician once every year.
1. Test the flow switch by disabling the boiler primary
loop circulator. The boiler must not start when there
is not water flow.
2. Follow the procedure for turning the boiler off per
Figure 47 “Operating Instructions”.
3. Inspect the wiring to verify the conductors are in
good condition and attached securely.
XI. Service and Maintenance (continued)
CAUTION / ATTENTION
Electrical Shock Hazard. Label all wires prior to
disconnection when servicing controls. Wiring
errors can cause improper and dangerous
operation. Verify proper operation after
servicing.
Au moment de l´entretien des commandes,
étiquetez tous les fils avant de les débrancher.
Les erreurs de câblage peuvent nuire au bon
fonctionnement et être dangereuses.
S´assurer que l´appareil fonctionne
adéquatement une fois k´entretien terminé.
4. Remove the igniter assembly and flame sensor and
inspect them for oxide deposits. Clean the oxide deposits
from the igniter electrodes and flame sensor rod with
steel wool. Do not use sandpaper for the cleaning.
Inspect the ceramic insulators for cracks and replace
the igniter assembly and/or flame sensor if necessary.
Check the igniter electrode spacing gap. Refer to Figure
63 “Igniter Electrode Gap” for details.
prohibited. Do not use any cleaning agents or solvents. If
insulation disc has signs of damage, it must be replaced.
9. 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
neutralizer and the drain. Clean/repair if needed.
If the condensate neutralizer is used, check pH before
and after the neutralizer to determine neutralizing
effectiveness. Replace limestone chips and clean out
the neutralizer if needed.
10. Inspect vent connections and vent connector to heat
exchanger seals to verify that they are free from
leakage and deterioration. Repair as needed. Follow all
instructions in Section IV “Venting” when reassembling
vent system.
11. Check for vent and air intake terminal for obstructions
and clean as necessary. Check screens in vent and air
intake terminations to verify they are clean and free
of debris.
WARNING
Failure to properly secure the burner/blower/gas
valve assembly to the heat exchanger could lead
to property damage, personal injury or loss of
life.
12. Reinstall the burner/blower/gas valve assembly and
secure with M6X1 hex flange nuts.
Figure 63: Igniter Electrode Gap
5. To gain access to boiler burner and combustion chamber,
first disconnect and remove gas inlet piping from gas
valve. Then, remove six M6X1 hex flange nuts and
take out the burner/blower/gas valve assembly from
the boiler. To prevent stud breakage, apply a generous
amount of good quality penetrating oil to nuts and let
it soak in prior to attempting nut removal.
6. Inspect the assembly for lint and dust presence. If
significant lint and dust accumulations are found,
disassemble the blower/gas valve assembly to expose
the swirl plate and blower inlet. For parts identification,
refer to Section XIII “Repair Parts”. Vacuum these parts
as required, being careful not to damage the vanes on
the swirl plate.
7. Vacuum any dust or lint from the burner if present. If
the burner shows any visual deterioration or corrosion
signs, replace it immediately. Inspect the burner gasket
and replace if necessary.
8. Inspect the heat exchanger combustion chamber, clean
and vacuum any debris found on the surfaces. If
required, brush the coils of the heat exchanger using a
non-abrasive, non-metal bristle brush. Any cleaning of
the combustion chamber with acid or alkali products is
13. Reconnect any wiring which has been disconnected.
14. Verify that the system pH is between 7.5 and 9.5.
15. Inspect the heating system and correct any other
deficiencies prior to restarting the boiler.
16. Follow Section IX “System Start-up” before leaving
installation.
17. Perform the combustion test outlined in Section IX
“System Start-up”.
D.Recommended Heating System Water
Treatment Products:
1. System Cleaning and Conditioning:
a. The following heating system water treatment
products are recommended for an initial existing
heating system sludge removal, initial boiler
cleaning from copper dust, flux residue and any
boiler debris and for preventive treatment as
corrosion/scale inhibitors:
i. Fernox™ Restorer (universal cleaner, sludge
remover, scale remover, flux residue/debris
remover, corrosion inhibitor)
ii. Fernox™ Protector (Alphi 11, CH#, Copal)
(sludge remover, corrosion inhibitor)
119
XI. Service and Maintenance (continued)
Follow manufacturer application procedure
for proper heating system/boiler cleaning and
preventive treatment.
Above referenced products are available from
Alent plc, Consumer Products Division, 4100
6th Avenue, Altoona, PA 16602, Tel: (972)
547-6002 and/or selected HVAC distributors.
Contact Thermal Solutions for specific details.
iii.Sentinel® X400 System Restorer (For Older
Closed Loop Hydronic Heating Systems)
iv.Sentinel® X300 System Cleaner (For New
Heating Systems)
v.Sentinel® X100 Inhibitor (For Protecting
Closed Loop Hydronic Heating Systems
Against Lime scale And Corrosion)
Follow manufacturer application procedure
for proper heating system/boiler cleaning and
preventive treatment.
Above referenced products are available from
Douglas Products and Packaging, 1550 E. Old
210 Highway, Liberty, MO 64068, Tel:(877)
567-2560 (Toll Free) and/or selected HVAC
distributors.
Contact Thermal Solutions for specific details.
WARNING
Poison Hazard. Use only inhibited propylene
glycol solutions specifically formulated for
hydronic systems. Do not use ethylene glycol,
which is toxic and can attack gaskets and seals
used in hydronic systems. Use of ethylene
glycol could result in property damage, personal
injury or death.
E. Condensate Overflow Switch and Condensate
Trap Removal and Replacement:
For removal or replacement of the condensate overflow
switch and/or condensate trap follow the steps below. For
parts identification, refer to Section XIII “Repair Parts”.
1. Condensate Overflow Switch Removal and
Replacement:
b. Equivalent system freeze protection products
may be used in lieu of product referenced above.
In general, freeze protection for new or existing
systems must use specially formulated glycol,
which contains inhibitors, preventing the glycol
from attacking the metallic system components.
Insure that system fluid contains proper glycol
concentration and inhibitor level. The system should
be tested at least once a year and as recommended by
the manufacturer of the glycol solution. Allowance
should be made for expansion of the glycol solution.
120
Figure 64: Condensate Overflow Switch Orientation
a. Disconnect power supply to boiler.
b. Remove 2 wire nuts and disconnect overflow switch
wire pigtails from boiler wiring.
c. Using pliers, release spring clip securing the
overflow switch to condensate trap body and remove
the switch. Note that the switch has factory applied
silicon adhesive seal, which may have to be carefully
cut all around to facilitate the switch removal.
d. Insure the trap overflow switch port is not obstructed
with silicon seal debris, clean as needed.
e. Apply silicon sealant to the replacement switch
threads and install the switch into the trap body
making sure it is properly oriented - the arrow
molded into the switch hex end side must face
down for proper switch operation. See Figure 64
“Condensate Overflow Switch Orientation” for
details.
f. Reconnect the switch wire pigtails to the boiler
wiring and secure with wire nuts.
g. Restore power supply to boiler. Fill up the trap
(see Section V “Condensate Disposal”) and verify
the switch operation.
XI. Service and Maintenance (continued)
2. Condensate Trap Removal and Reinstallation:
a. Disconnect power supply to boiler.
b. Remove 2 wire nuts and disconnect overflow switch
wire pigtails from boiler wiring.
c. Disconnect pressure switch hose from condensate
trap.
d. Disconnect outside condensate compression fitting
from condensate trap.
e. Using pliers, release spring clip securing the
overflow switch to condensate trap body and remove
the switch. Note that the switch has factory applied
silicon adhesive seal, which may have to be carefully
cut all around to facilitate the switch removal.
f. Using pliers, release spring clip securing condensate
trap body to the heat exchanger bottom drain
connection.
g. First, pull the trap downwards to release from the
heat exchanger. Second, pull the trap end from left
side jacket panel sealing grommet and remove the
trap from boiler.
h. To reinstall the trap, reverse above steps.
i. If the original condensate overflow switch is to
be re-used, follow the appropriate switch removal
steps from Condensate Overflow Switch Removal
and Replacement procedure above.
j. Insure that fresh silicon sealant is applied to the
overflow switch threads and the switch is properly
oriented relative to the trap body - the arrow molded
into the switch hex side end must face down for
proper switch operation. See Figure 64 “Condensate
Overflow Switch Orientation” for details.
k. Insure that pressure switch hose is reconnected to
the trap.
l. Restore power supply to boiler. Fill up the trap
(see Section V “Condensate Disposal”) and
verify the switch operation.
F. Control Compartment Access
1. Non-stacked boiler installations: Remove top
front panel to access control compartment.
2. Stacked boiler installations: Remove front
door and display panel. As shown in Figure
65, remove two screws, one inside junction
box and one on right side panel. Swing
control panel downward to access control
compartment.
Figure 65: Control Compartment Access for Stacked Boiler Installations
121
XII. Troubleshooting
WARNING
Electrical Shock Hazard. Turn off power to boiler before working on wiring.
A. Help Menu Navigation
When a fault is active, the Help icon flashes red on the
Home Screen. See Figure 66. To investigate a fault,
select Help. Continue selecting the flashing icons to be
directed to the fault cause.
Figure 66: Help Menu Navigation
122
XII. Troubleshooting (continued)
B. Troubleshooting when Help
icon NOT flashing:
Indication
Condition
Boiler not responding to demand.
Status and Priority show
Standby.
Demand not
detected
Boiler not responding to demand.
Status shows Standby and
Priority shows Central Heat or
Domestic Hot Water.
Boiler not
running,
pump(s)
running
Boiler running but System Pump
or Boiler Pump is not running
Pump(s) not
running
Display completely dark, fan off,
LWCO lights off, no green power
light on boiler control
No 120VAC
power at boiler
Display completely dark, green
power light illuminated on boiler
control
No 24VDC
power at
display
Possible Cause
•
•
Boiler not seeing Enable/Disable or DHW Demand input. Check wiring
for loose connections or miswiring.
If DHW Demand is expected, check that Domestic Hot Water
parameters are selected properly.
Boiler not firing because temperature greater than Setpoint. Wait for
temperature to drop below Setpoint minus Differential Below or adjust
Setpoint as needed.
•
•
Check wiring for loose connections or miswiring.
When there is DHW Demand: Boiler Pump will be off if set to Central
Heat, Off DHW Demand and System Pump will be off if set to Central
Heat, Optional Priority. This feature allows for fast indirect water heater
recovery. After Priority Time has expired or DHW Demand ends, Boiler
Pump and System Pump are free to run for Enable/Disable demand.
Circuit breaker tripped. Check breaker and wiring between breaker and
boiler.
•
•
Loose 120VAC wiring connection between J-box and display power
supply.
Loose 24VDC wiring connection between power supply and display.
Display blank with “Reading”
shown
Display lost
communication
with control
Communication Error 2
The display write attempt has failed.
• Password level is too low for parameter being changed
Communication
• Boiler control is un-configured or has a memory failure. Lockout 20
Fault
Safety Data Verification will be displayed if control is not configured or
has had a memory loss. In this case replace control.
Communication Error 3
Display has lost communication with control.
If no green power light on control, check for:
• Blown 24V fuse on low voltage PCB. Check for 24V shorts before
replacing fuse.
• Loose or defective wiring between transformer and control.
Communication • Bad transformer
Fault
If green power light is illuminated on control, check for:
• Loose or defective wiring between display and control
• Defective display
• Defective control
• Incorrect COM Port parameters. Refer to EMS Modbus Parameters in
Parameter Adjustment section.
Blinking green power light on
boiler control
Control Fault
Failure to establish communication upon display boot-up. After establishing
communication, reboot display to read controller and setup display properly.
The green light is connected to internal power supply. The power supply is
repeatedly starting and stopping (not normal) making the light flash. The
microprocessors are not running. Try disconnecting all terminals except
24VAC to power the control. The green light should be steady. If it is not,
then the control is defective. If steady, start plugging in all the connectors
while watching the green light. When faulty wiring is reconnected, green
light will begin to flash.
123
XII. Troubleshooting (continued)
C. Soft Lockout (Hold)
From the Help menu, select the blinking Soft Lockout (Hold) icon to determine the cause of the soft lockout. See Figure 67.
The boiler will automatically restart once the condition that caused the lockout is corrected.
Figure 67: Example Soft Lockout
The Soft Lockout (Hold) screen will display the hold number, name, condition that caused the hold, possible causes, and a
basic description of corrective actions that may be taken to fix the problem. An in-depth guide to possible soft lockouts is
provided in Table 56.
Table 56: Soft Lockout (Hold) Codes
Lockout
Number
Condition
1
Anti-Short Cycle
Minimum time between starts has
not been reached. Normal delay
used to avoid excessive cycles.
2
Boiler Recycling
Limits Open
(LCI OFF)
3
Burner Interlock
Open (ILK OFF)
4
Outlet/Supply
High Limit
6
Stack High Limit
124
Possible Cause
Faulty contact provided by the EMS system.
LCI safety limit input not energized.
Limit Control Input (LCI) is not ON. Refer to Limit String Status screen
for list of limits.
• Auto Reset Ext. Limit device open or jumper not installed
• Low water condition (if using 24V LWCO)
• Flow switch open. Check boiler pump and flow switch wiring.
• Sump pressure switch open. Check for vent or combustion air
pipe blockage.
• Condensate float switch open. Check for condensate drain
blockage.
• Loose or defective limit string wiring
ILK safety limit input not energized.
Lockout input (ILK) is not ON. Refer to Limit String Status screen for
list of limits.
• Man Reset Ext. Limit device open or jumper not installed
• High or low gas pressure switch open or jumper not installed
• Thermal link open
• Burner door thermostat open
• Loose or defective limit string wiring
•
Supply temperature exceeds
•
Preferred Supply High Limit minus
•
Stepped Modulation Recycle Offset,
•
default 200°F (93.3°C).
Heating load much less than boiler minimum firing rate.
Defective system pump or no flow in primary loop.
Defective boiler pump, no flow or insufficient flow in boiler loop.
Control system miswired so that the boiler operation is permitted
when no zones are calling.
Flue temperature exceeds
•
Preferred Stack High Limit minus
•
Stepped Modulation Recycle Offset,
•
default 194°F (90°C).
Heat exchanger needs to be cleaned
Boiler over-fired
Air-fuel mixture out of adjustment
XII. Troubleshooting (continued)
Table 56: Soft Lockout (Hold) Codes (continued)
Lockout
Number
Condition
7
Return Sensor
Fault
Shorted or open return
temperature sensor.
8
Supply Sensor
Fault
Possible Cause
•
•
Shorted or open supply temperature •
sensor.
•
Shorted or miswired return sensor wiring
Defective return sensor
Shorted or miswired supply sensor wiring
Defective supply sensor
9
DHW Sensor
Fault
Shorted or open Domestic Hot
Water (DHW) temperature sensor.
•
•
Shorted or miswired DHW sensor wiring
Defective DHW sensor
10
Stack Sensor
Fault
Shorted or open flue gas (stack)
temperature sensor.
•
•
Shorted or miswired flue sensor wiring
Defective flue sensor
13
Flame rod
shorted to ground
Flame rod shorted to ground
•
•
Shorted or miswired flame rod wiring
Defective flame rod
14
Delta T Inlet/
Outlet High
Temperature rise between supply
and return is too high.
15
Return
Temperature
Higher Than
Supply
•
Return temperature was greater
than supply temperature for at least •
75 seconds.
•
16
Supply
Supply water temperature has risen
Temperature
too quickly.
Risen Too Quickly
17
Fan Speed Not
Proved
27
Interrupted
Airflow
Switch (IAS) ON
27
Interrupted
Airflow Switch
(IAS) OFF
Inadequate boiler water flow.
• Boiler pump not operating
• Boiler pump undersized
• Valve closed
Normal waiting for blower speed to
match purge and light-off setpoint.
Air proving switch failed to open.
Air proving switch failed to close.
Reversed flow through boiler. Verify correct piping and circulator
orientation.
No boiler water flow. Verify system is purged of air and appropriate
valves are open.
Defective supply or return sensor
Inadequate boiler water flow. See also causes for Hard Lockout 4.
• Boiler pump not operating
• Boiler pump undersized
• Valve closed
N/A
Air proving switch closed before Prepurge.
• Failed air proving switch. Check switch for proper operation.
• Short in limit string wiring
Air proving switch open during Prepurge or Drive Lightoff.
• Check for vent or combustion air pipe blockage.
• Confirm air proving switch hose connected to gas valve outlet
tapping and outlet tapping internal screw is open.
• Loose or defective limit string wiring
125
XII. Troubleshooting (continued)
D. Hard Lockout
From the Help menu, select the blinking Hard Lockout icon to determine the cause of the hard lockout. See Figure 68. The
boiler will automatically restart once the condition that caused the lockout is corrected.
Figure 68: Example Hard Lockout
The Hard Lockout screen will display the lockout number, name, condition that caused the lockout, possible causes, and a
basic description of corrective actions that may be taken to fix the problem. An in-depth guide to possible hard lockouts is
provided in Table 57.
Table 57: Hard Lockout Codes
Lockout
Number
3
Burner Interlock
Open (ILK OFF)
Condition
ILK safety limit input not energized
4
Outlet/Supply
High Limit
Supply temperature exceeded fixed
high limit, 210°F (98.9°C).
6
Stack High Limit
Flue temperature exceeded
204°F (95.6°C).
12
Flame detected
out of sequence
A flame signal was present when
there should be no flame.
14
Delta T Inlet/
Outlet High
Temperature rise between supply
and return is too high.
126
Possible Cause
Lockout input (ILK) is not ON. Refer to Limit String Status screen for
list of limits.
• Man Reset Ext. Limit device open or jumper not installed
• High or low gas pressure switch open or jumper not installed
• Thermal link open
• Burner door thermostat open
• Loose or defective limit string wiring
•
•
•
•
Heating load much less than boiler minimum firing rate.
Defective system pump or no flow in primary loop.
Defective boiler pump, no flow or insufficient flow in boiler loop.
Control system miswired so that the boiler operation is permitted
when no zones are calling.
•
•
•
Heat exchanger needs to be cleaned
Boiler over-fired
Air-fuel mixture out of adjustment
-
Defective gas valve - make sure inlet pressure is below maximum
on rating plate before replacing valve.
Inadequate boiler water flow.
• Boiler pump not operating
• Boiler pump undersized
• Valve closed
XII. Troubleshooting (continued)
Table 57: Hard Lockout Codes (continued)
Lockout
Number
Condition
Possible Cause
15
Return
Temperature
Higher Than
Supply
•
Return temperature was greater
than supply temperature for at least
75 seconds.
•
Reversed flow through boiler. Verify correct piping and circulator
orientation.
No boiler water flow. Verify system is purged of air and appropriate
valves are open.
Defective supply or return sensor
16
Supply
Temperature
Risen Too
Quickly
•
Supply water temperature has risen •
too quickly.
•
•
Inadequate boiler water flow. See also causes for Hard Lockout 4.
Boiler pump not operating
Boiler pump undersized
Valve closed
18
Light-off Rate
Proving Failed
Blower not running at requested
light-off rate or blower speed signal
not detected
•
•
•
Loose connection in 120 VAC blower wiring
Loose or miswired blower speed harness
Defective blower
19
Purge Rate
Proving Failed
Blower not running at requested
purge rate or blower speed signal
not detected
•
•
•
Loose connection in 120 VAC blower wiring
Loose or miswired blower speed harness
Defective blower
20
Configuration
Fault
Unacceptable control safety
parameter detected. See display
for details.
Safety parameter verification required. Contact factory.
21
Invalid
Modulation
Parameters
Unacceptable control modulation
parameter detected.
Reset control. If problem persists, contact factory.
22
Safety Data
Verification
Needed
Safety parameter change detected
and verification has not been
completed.
•
•
•
•
•
•
Safety related control parameter has been changed and
verification
has not been performed.
Control not programmed. Contact factory.
Loose connection in 24VAC power wiring.
Loose or miswired 24VAC harness.
Miswired wiring harness causing power supply short to
ground.
Defective transformer.
Transformer frequency, voltage and VA do not meet specifications.
23
24VAC Voltage
Low/High
Control 24VAC control power is
high or low.
24
Fuel Valve Error
Power detected at fuel valve output
when fuel valve should be off.
25
Hardware Fault
Internal control failure.
See display for details.
Reset control. If problem recurs, replace control.
26
Internal Fault
Internal control failure.
Reset control. If problem recurs, replace control.
•
•
•
•
•
•
•
27
Ignition Failure
Flame not detected at end of
ignition sequence.
•
•
•
•
•
Loose or defective gas valve harness. Check electrical
connections.
Defective gas valve. Before replacing valve, check for 24 VAC at
gas valve connector during trial for ignition.
Gas line not completely purged of air.
Gas pressure too low. See minimum on boiler rating label.
Air-fuel mixture out of adjustment. See System Start-Up
Section.
Disconnected or defective igniter wire.
Disconnected or defective flame sensor wire.
Defective igniter electrode.
Defective flame sensor.
Defective gas valve. Before replacing valve, check for 24
VAC at gas valve connector during trial for ignition.
127
XII. Troubleshooting (continued)
Table 57: Hard Lockout Codes (continued)
Lockout
Number
Condition
27
Interrupted
Airflow
Switch (IAS) ON
Air proving switch failed to open.
Air proving switch closed before Prepurge.
• Failed air proving switch. Check switch for proper operation.
• Short in limit string wiring
27
Interrupted
Airflow Switch
(IAS) OFF
Air proving switch failed to close.
Air proving switch open during Prepurge or Drive Lightoff.
• Check for vent or combustion air pipe blockage.
• Confirm air proving switch hose connected to gas valve outlet
tapping and outlet tapping internal screw is open.
• Loose or defective limit string wiring
42
AC Phase Fault
AC inputs phase reversed
47
Flame Lost
Flame lost at some stage. See
display for details.
284
Memory Reset To
Default
OEM Memory Lost, Honeywell
Default Memory Restored
128
Possible Cause
•
•
•
Check control and display connections.
Verify line voltage frequency and voltage meet specifications.
Verify 24VAC transformer functioning properly.
•
•
•
•
•
Gas pressure too low. See minimum on boiler rating label.
Air-fuel mixture out of adjustment. See System Start-Up Section.
Disconnected or defective flame sensor wire.
Defective flame sensor.
Defective gas valve. Before replacing valve, check for 24 VAC at
gas valve connector during trial for ignition.
•
•
•
Control failure
Consult factory
Replace control
XII. Troubleshooting (continued)
E. Limit String Status
From the Help Menu, select Limit String Status to view status of individual safety limits. See Figure 69. ON indicates closed
limit contact. OFF with red background indicates open limit contact. When a limit is OFF, all limits connected to the same
control terminal (e.g. A2) and will show OFF. Limits downstream (below) the OFF limit and connected to a different control
terminal may also show OFF. When troubleshooting, check OFF limits in order from top to bottom to isolate the problem.
Air proving switch and flow switch limits cycle normally based on function of boiler. Refer to Figure 40, Ladder Diagram
for limit string details.
Control Terminal
Figure 69: Limit String Status
E. Sensor Status
Select Sensor Status from the Help Menu or Sensors from the Main Menu to view status of individual sensors. Select an
individual sensor to display gauge reading on right side of display. A failed sensor is shown with a red background as in
Figure 70. See Table 58 for sensor fault diagnostic help and Tables 59 through 62 for sensor temperature versus resistance
values.
Figure 70: Sensors Screen with Shorted Supply Sensor
129
XII. Troubleshooting (continued)
Table 58: Sensor Fault Diagnostic Help
Indication
Possible Cause
Sensor has not been selected. For example, in Figure 70, the Header Sensor has not been
selected. Refer to Operations Section, Parameter Adjustment for information on how to select
sensors.
Not Installed
Open
Sensor not connected or loose wire. Check sensor wiring.
Sensor terminals connected to each other or sensor has failed.
• Check sensor wiring.
• Check sensor resistance. See Tables 59 through 62 for temperature versus resistance
values.
Shorted
Outside low range
Outside high range
Sensor input out of range. Sensor is defective or is being subjected to electrical noise.
Not reliable
Sensor is defective or is being subjected to electrical noise.
Table 59: Supply and Flue Sensor
Temperature vs. Resistance,
10kOhm NTC, Beta = 3977K
Temperature
130
Ohms of
Resistance
Table 60: Return Sensor
Temperature vs. Resistance,
12kOhm NTC, Beta = 3750K
Temperature
°F
°C
Ohms of
Resistance
°F
°C
32
0
32650
32
0
36100
41
5
25390
50
10
22790
50
10
19900
68
20
14770
59
15
15710
77
25
12000
68
20
12490
86
30
9810
77
25
10000
104
40
6653
86
30
8057
122
50
4610
95
35
6531
140
60
3250
104
40
5327
158
70
2340
113
45
4369
176
80
1710
122
50
3603
194
90
1270
131
55
2986
212
100
950
140
60
2488
230
110
730
149
65
2083
248
120
560
158
70
1752
167
75
1481
176
80
1258
185
85
1072
194
90
918
203
95
789
212
100
680
XII. Troubleshooting (continued)
Table 61: Outdoor Sensor
Temperature vs. Resistance,
10kOhm NTC, Beta = 3435K
Outdoor Temperature
Table 62: Header Sensor
Temperature vs. Resistance,
10kOhm NTC, Beta = 3950K
Temperature
°F
°C
Ohms of
Resistance
-20
-28.9
106926
32
0
32648
-10
-23.3
80485
50
10
19898
0
-17.8
61246
68
20
12492
10
-12.2
47092
77
25
10000
20
-6.7
36519
86
30
8057
30
-1.1
28558
104
40
5327
°F
°C
Ohms of
Resistance
40
4.4
22537
122
50
3602
50
10.0
17926
140
60
2488
60
15.6
14356
158
70
1752
70
21.1
11578
176
80
1256
76
24.4
10210
194
90
916
78
25.6
9795
212
100
697
80
26.7
9398
248
120
386
90
32.2
7672
100
37.8
6301
110
43.3
5203
120
48.9
4317
131
XII. Troubleshooting (continued)
F. Additional Help Menu Icons
A summary of additional icons that may be flashing on the Help Menu is provided in Table 63.
WARNING
Asphyxiation Hazard. Boiler type is factory set and must match the boiler model. Only change the boiler
type setting if you are installing the boiler at altitudes above 2000 ft or if you are replacing the 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.
Table 63: Additional Help Menu Icons
Flashing Red
Outline
Condition
Possible Cause
Firing rate is limited or reduced to help avoid unnecessary cycling
or lockout. Refer to Soft and Hard Lockout sections for potential
corrective action.
Boiler firing rate is limited
Boiler size fault
Boiler Type/Size setting may not match actual boiler size. This setting
determines min, max and light-off blower speeds
Sequencer communication fault
Slave boiler has lost communication with Sequencer Master. Restore
communication or cycle power to clear fault. Check for the following:
• Loose or defective boiler-to-boiler communication wiring
• Sequencer Master was Enabled and then Disabled
• Loss of power to Sequencer Master boiler
EMS interface fault
There is a fault with the Energy Management System (EMS) interface.
Signals received from the EMS are listed with selection status and
present value.
Service
Contact *
Manual reset hard lockout *
132
Rate limiting occurs during normal operation under any of these
conditions.
• Minimum Modulation (normal start/stop sequence )
• Forced Modulation (normal start/stop sequence)
• Burner Control Rate (normal start/stop sequence)
• Manual Firing Rate ( user selected)
• Low Fire Hold Time period after startup (user adjustable)
Rate limiting occurs for boiler protection under any of these conditions.
• Supply temperature > Stepped Modulation Start Offset
• Differential temperature > Stepped Modulation Start Offset
• Flue Temperature > Stepped Modulation Start Offset
User is given contact information of the responsible installing
contractor, service company, representative and manufacturer. Refer
to Parameter Adjustment, Service Contacts section.
When the lockout condition has been cleared, manual reset hard
lockouts may be reset here or by pressing button on top of control.
XII. Troubleshooting (continued)
H. Archives
Select Archives from the Main Menu to view
boiler historic boiler operating data. See
Figure 71. Archives allow user to review up
to four months of sensor values, up to 3000
alarms, lockout history, and cycle and run time
history. Data may be viewed on screen or
exported to a thumb drive for detailed analysis.
Figure 71: Archives Screen
1. Supply/Return Temperature History / Flame Intensity History / Fan Rate History
Supply, return, flame and fan data provides an opportunity to investigate issues, learn about system operation or fine
tune the boiler. Historical data values are viewed by scrolling left and right; the further left, the older the data. As shown
in Figure 72, touch the trend at any location to display exact data points as well as date and time at which they were
recorded.
Figure 72: Display of Exact Data Points with Date and Time
2. Lockout History
Lockout History stores up to 15 lockouts in a first-in, first-out basis, 1 being the newest. See Figure 73. Each lockout
file is stored with boiler run hour of when the lockout occurred, status at time of lockout, and limit string annunciator that
caused the lockout (if applicable). Touch a specific lockout to display more information.
Figure 73: Lockout History
133
XII. Troubleshooting (continued)
3. Cycle & Run Time History
Cycle and Run time data is provided for control, boiler and pumps. Additionally, a load profile is collected. Graphs are
provided that show amount of time the boiler operated at each load point. Data may be reset. See Figure 74.
Figure 74: Example Cycle & Run Time History
4. Alarm History
Up to 3000 alarms may be recorded with date and time stamp. These include lockouts, holds, sensor faults, EMS
communication error or loss, boiler-to-boiler communication loss, 4-20mA errors, and limit string cycling. Scroll through
alarm list to investigate most recent and past alarms on screen, most recent appearing at bottom. See Figure 75. Use the
Save Historical Data function to download alarm list to a USB thumb drive in spreadsheet form for better troubleshooting.
Figure 75: Example Alarm List
5. Save Historical Data to USB
NOTICE
Save Historical Data to USB takes several minutes to complete. Do not remove flash drive until display shows download
is complete.
Insert USB thumb drive into USB port, then Select Save Historical Data to USB to download historical parameters and
alarms as spreadsheets. See Operation Section, Parameter Adjustment for USB thumb drive requirements.
134
Files are saved as with a date code when they were saved from the boiler. For example, 20140612 = June 12, 2014. An
example file path is shown in Figure 76: My Computer >> Removable Disk >> HMI >> HMI-000 >> @HMI0001 >>
CSV. The highest number folder name is the newest data. In example shown, @HMI0001 is newer than @HMI0000. If
another set of historical data is saved, the new file will be @HMI0002.
XII. Troubleshooting (continued)
Figure 76: Example USB Drive File Path
Figure 77 shows an example of the Trend1-20141022.csv file contents. Boiler state is defined in Table 64. Figure 78
shows an example of the Alarm-20140612.csv file contents.
Figure 77: Example Trend File Contents
135
XII. Troubleshooting (continued)
Figure 78: Example Alarm File Contents
Table 64: Boiler State
No.
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
136
Boiler State
Initiate
Standby delay
Standby
Safe Startup
Drive Purge
Prepurge
Drive Lightoff
Preignition Test
Preignition
PFEP (pilot flame establishing period)
MFEP (main flame establishing period)
Direct Ignition
Running
Postpurge
Lockout
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
parts, please contact Thermal Solutions Customer Service at (717) 239-7642 or Fax (877) 501-5212.
137
138
SIZE 399-525 ONLY
XIII. Repair Parts (continued)
XIII. Repair Parts (continued)
Heat Exchanger Components
Part Number
Key
Description
No.
APX425C APX525C APX625C APX725C APX825C
Replacement Heat Exchanger Assembly (includes bare heat
exchanger, supply and return water temperature sensors, air 106464-01 106278-01
106465-01
vent valve and water gaskets)
1A Air Vent Valve
101586-01
1B Supply Water Temperature Sensor / High Limit Sensor
106014-01
1C Return Water Temperature Sensor
101685-01
1D Flue Temperature Sensor
106015-01
1E Flue Sensor Grommet
105997-01
Replacement Thermal Link and Rear Insulation Disc Kit
(includes thermal link, disc, hardware, and instructions)
Replacement Rear Insulation Disc Kit (includes disc,
1G
hardware, and instructions)
Flue Exit Gasket Replacement Kit (includes gasket and
1H
dielectric grease)
1J 4” Flue Collar Adapter
105996-01
N/A
1K Temperature and Pressure Gauge (not shown)
100282-01
103470-02
1F
Safety Relief Valve (not shown)
Alternate Safety Relief Valve Kit (not shown, includes safety
relief valve and temperature and pressure gauge)
1M Boiler Drain Valve, 3/4 in. NPT (not shown)
1L
106279-01
104998-01
105651-01
104501-01
104502-01
50 PSI: 103837-01
60 PSI: 81660375
80 PSI: 104200-01
100 PSI: 104201-01
806603061
Burner Components
Key
Description
No.
Part Number
APX425C APX525C APX625C APX725C APX825C
1N
Replacement Burner Kit (includes burner, burner gasket,
and hardware)
104988-01
1O
Replacement Burner Door Kit (includes door with inner
and outer seals, gaskets for sensor and igniter, insulation,
and thermostat; does not include igniter or flame sensor)
104992-01
104993-01
1P
Burner Door Insulation Kit (WARNING: Contains RCF)
105650-01
105674-01
1Q
Replacement Flame Sensor Kit (includes sensor, gasket,
and hardware)
103339-01
103310-01
1R
Replacement Igniter Kit (includes igniter, gasket, and
hardware)
103005-01
103308-01
1S
Replacement Gas/Air Duct Kit (includes duct, gaskets,
and hardware)
104994-01 106510-01
1T
Burner Gasket
102739-01
104986-01
1U
Burner Door Outer Seal
101730-01
104985-01
1V
Burner Door Thermostat with Manual Reset
104569-01
1W
Burner Door Hex Flange Nut, M6 x 1.0 mm (6 per boiler)
101724-01
104990-01
104991-01
104996-01
139
140
XIII. Repair Parts (continued)
XIII. Repair Parts (continued)
Blower / Gas Train Components
Key
Description
No.
Part Number
APX425C
APX525C
2A
Replacement Blower Kit (includes blower, blower outlet gasket and hardware)
104999-01
104999-02
2B
Blower Outlet Gasket
101345-01
105995-01
2C
Blower Inlet Assembly (includes gas orifice, injector flange, inlet shroud (425C
only), swirl plate, blower adapter plate, and mounting hardware)
101704-04
101704-05
2D
Blower Inlet Replacement Kit (includes swirl plate, blower adapter plate, and
mounting hardware)
104620-04
104620-05
2E
Replacement Gas Valve Kit (includes one gas valve and o-rings)
105004-01
105004-04
2F
Gas Valve 90° Flange Kit (includes one 90° flange, o-ring, and hardware)
N/A
102972-03
2G
Gas Valve Wire Harness (includes harness with plug and M4 x 30 mm screw)
2H
Gas Valve Straight Flange Kit (includes one straight flange, o-ring, and hardware
2J
Gas Line Rubber Grommet
3/4 in. NPT: 101638-01
2K
Gas Shutoff Valve
3/4 in. NPT: 101615-01
2L
Air Proving Switch
2M
Air Proving Switch Tubing, silicone, 5/16 in. ID x 0.07 in. Wall Thickness x 18 in.
long
102971-01
N/A
105976-01
102972-02
105549-01
106460-01
141
142
XIII. Repair Parts (continued)
APX625C, APX725C and APX825C
(APX825C shown)
XIII. Repair Parts (continued)
Blower / Gas Train Components
Key
Description
No.
Part Number
APX625C
APX725C
2A
Replacement Blower Kit (includes blower, blower outlet gasket
and hardware)
104999-03
2B
Blower Outlet Gasket
103263-01
2C
Blower Inlet Assembly (includes gas orifice, injector flange, inlet
shroud (425 only), swirl plate, blower adapter plate, and mounting
hardware)
2D
Blower Inlet Replacement Kit (includes swirl plate, blower adapter
plate, and mounting hardware)
2E
Replacement Gas Valve Kit (includes one gas valve and o-rings)
2F
Gas Valve 90° Flange Kit (includes one 90° flange, o-ring,
and hardware)
2G
Gas Valve Wire Harness (includes harness with plug and
M4 x 30 mm screw)
2H
Gas Valve Straight Flange Kit (includes one straight flange, o-ring,
and hardware
Natural Gas:
105001-01
Natural Gas:
105001-02
LP Gas:
105000-01
LP Gas:
105000-02
N/A
N/A
Gas Shutoff Valve
2L
Air Proving Switch
2M
Air Proving Switch Tubing, silicone, 5/16 in. ID x 0.07 in.
Wall Thickness x 18 in. long
103223-01
N/A
Natural Gas: 105004-04
LP Gas: 105004-03
102972-03
Natural Gas: 103225-01
LP Gas: 103300-01
N/A
N/A
N/A Gas Line Rubber Grommet
2K
APX825C
N/A
1 in. NPT: 103252-01
1 in. NPT: 816SOL0015
105998-01
106002-01
106460-01
143
XIII. Repair Parts (continued)
Condensate Trap and Related Components
Key
Description
No.
Part Number
APX425C APX525C APX625C APX725C APX825C
3A
Replacement Condensate Trap Kit
(includes trap, float switch, grommet, coupling, and
clamps)
3B
Replacement Condensate Float Switch Kit
(includes float switch and clamp)
105005-01
3C
Spring Hose Clamp, 15/16 in. OD hose
101632-01
3D
Rubber Grommet, Condensate Trap
101595-01
3E
Condensate Neutralizer Kit
(not shown, includes limestone chips)
101867-01
3F
Limestone Chips, 2 lb. bag (not shown)
101873-01
3G
Sump Pressure Switch
3H
Air Pressure Switch Tubing, Silicone, 3/16 in. ID x 0.07
in. Wall Thickness
144
104704-01
105006-01
104426-01
13.5 in.
7016041
105999-01
22 in.
102770-01
24 in. 104658-01
106414-01
28 in.
103257-01
XIII. Repair Parts (continued)
Control Components
Key
No.
4A
4B
4C
4D
Description
Replacement Control Kit (programmed)
Replacement Display Kit (programmed, includes
mounting hardware)
Display Power Supply
4G
Transformer
Replacement 120V PCB Kit (includes PCB, fuses,
and hardware)
Replacement Low Voltage PCB Kit (includes PCB,
fuses, and hardware)
Pump Fuse, 5x20mm, 6.3A Slow Blow
4H
24V Fuse, 5x20mm
4E
4F
Part Number
APX425C
APX525C APX625C
106499-01
APX725C APX825C
106499-02
106507-01
105994-01
102516-01
103193-01
106512-01
106513-01
4J
Machine Screw, 8-32 x 1/2 in.
105300-01
2.0A, Fast-Acting
106073-01
101033-01
4K
Strain Relief Cable
106016-01
4L
Display Panel
106269-01
4M
Display Panel End Cap, with USB Cutout
106268-01
4N
Display Panel End Cap
106267-01
1.6A, Slow-Blow
105299-01
145
146
XIII. Repair Parts (continued)
XIII. Repair Parts (continued)
Jacket and Trim Components
Key
Description
No.
Part Number
APX425C
APX525C APX625C APX725C APX825C
5A
Left Side Panel
106249-01
106249-02
106249-03
106249-04
5B
Right Side Panel (includes rating label instructions)
106517-01
106517-02
106517-03
106517-04
5C
Top Panel (includes gaskets)
106254-01
106254-02
106254-03
106254-04
5D
Top Control Access Panel (includes label)
5E
Front Door (includes gaskets and labels)
5F
Replacement Door Latch Kit (includes latch, cam, and
hardware)
5G
Rear Panel (includes gaskets)
5H
Junction Box Access Panel, 5.5 in. x 10.5 in.
5J
Access Panel, 5 in. x 8 in. (includes gasket)
5K
Gas Train Support Bracket
5L
U-Bolt for Gas Train Bracket
5M
Nylon Glide Replacement Kit
106518-01
106516-01
106516-02
106509-01
106253-01
106253-02
106253-03
106261-01
106255-01
102611-01
106074-01
3/4 in. OD Pipe
102622-01
106075-01
1-3/4 in. OD Pipe
105563-01
105014-01
5O
Vent Connector for CPVC/PP/SS (includes jacket
gasket and vent pipe gaskets)
Combustion Air Connector, 4 in. PVC Adapter
5P
Combustion Air Connector Gasket
105587-01
5Q
Combustion Air Connector Locknut, 4 in. Steel
105990-01
5N
4 in. (100 or 110 mm)
106017-01
6 in. (150 or 160 mm)
106018-01
105991-01
147
XIII. Repair Parts (continued)
Additional Components
Key
No.
Description
6A-1 Manual Reset High Limit (not shown)
Part Number
APX425C APX525C APX625C APX725C APX825C
106056-01
N/A
CSD-1 Kit (not shown, includes gas pressure switches)
Contact Thermal Solutions for LP boilers
N/A
107421-01
6B
Gas Pressure Switch Assembly
N/A
106356-01
6C
Low Gas Pressure Switch
N/A
107654-01
6D
High Gas Pressure Switch
N/A
107653-01
6E
N/A
106345-01
6L
Gas Pressure Switch Wire Harness
Flow Switch Kit
(not shown, includes switch and paddles)
Flow Switch Repair Paddle Kit (not shown, includes
paddles and hardware)
Outdoor Temperature Sensor (not shown)
Header Sensor for Direct Immersion, 1/2 in. NPT
(not shown)
Header Sensor Kit
(not shown, includes mounting hardware)
30 in. Long Schedule 40 CPVC Pipe (not shown)
4 in. 102193-02
6 in. 103267-01
6M
Schedule 80 CPVC 90° Elbow (not shown)
4 in. 102192-02
6 in. 103268-01
6N
Rodent Screen (not shown)
4 in. 102191-02
6 in. 102191-03
6A-2
6F
6G
6H
6J
6K
148
106383-01
106384-01
102946-01
101935-01
103104-01
XIII. Repair Parts (continued)
10A
10D
10E
10B
10C
10F
149
XIII. Repair Parts (continued)
10G
10H
10J
Wiring Harnesses
Key
No.
10A
10B
10C
10D
10E
10F
10G
10H
10J
150
Description
120V Harness
Low Voltage Harness
Fan Power Harness
Ignition Harness
USB Harness
Delta Display Power Harness
Delta Display Communication Harness
Flow Switch Harness
LWCO Jumper
Part Number
APX425C APX525C APX625C APX725C APX825C
106003-01
106008-01
103012-01
107211-01
106001-01
106006-01
106004-01
106385-01
105111-01
Appendix A - Instructions for High Altitude Installations Above 2000 ft.
WARNING
If installing APX525C or APX725C: Do not convert APX525C to LP gas (propane) at altitudes above 6000 ft.
Also, do not install APX725C LP gas (propane) 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 air free)
poisoning.
These instructions apply only to the following Apex boiler configurations: 2001 ft- 4500 ft, 4501 ft- 6000 ft, 6001 ft7800 ft, 7801 ft - 10,000 ft.
These instructions contain specific instructions to properly set up your boiler to ensure proper operation.
WARNING
LP Conversions - Apex boiler setup from factory is configured for use with natural gas installed from
0 - 2000 ft above sea level only. For APX425C or APX525C conversion to LP at altitude above 2000 ft,
follow these instructions as specific instructions must be followed when converting for use with LP. If
the information in these instructions is not followed exactly, a fire, an explosion or production of carbon
monoxide may result causing property damage, personal injury or loss of life. The qualified service agency
is responsible for proper installation of this boiler for use with LP gas. The installation is not proper and
complete until the operation of the converted appliance is checked as specified in the manufacturer’s
instructions supplied. APX625C, APX725C and APX825C are factory shipped as either natural gas build or
LP gas build. Field conversions of APX625C, APX725C and APX825C are not permitted.
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 air free) levels in
flue gas. Adjusting the air-fuel mixture without a proper combustion analyzer could result in unreliable boiler
operation, personal injury, or death due to carbon monoxide poisoning.
WARNING
Failure to set up the Boiler in accordance with these instructions could result in high amount of Carbon
Monoxide to be produced which could result in death, serious injury, and/or reduced component life.
Adjusting Boiler Type (must be completed first)
Select the correct Apex boiler size and altitude
range using the touch screen display as follows:
1. Check boiler’s label for actual boiler size.
2. Confirm installation altitude
3. Power up the boiler. Display will show the
Home screen.
4. Press main menu on home screen.
5. Press Adjust.
6. Press Modulation.
7. Press Lock. Enter password “86” and select
enter.
8. Press Boiler Model.
9. Press Adjust on Boiler Type screen.
10. Use the ↓ ↑ arrows to select the correct size and
altitude of your boiler. Press the
button to
enter your selection. See Figure 60.
Figure 60: Boiler Model (Boiler Type) Decoding
151
Appendix A - Instructions for High Altitude Installations Above 2000 ft. (continued)
11. Press “Confirm” until display stops blinking.
12. Press return arrow to go back to home screen.
Start-up Instructions for Natural Gas or LP
1. Confirm Apex boiler size, type and installed
altitude prior to startup.
2. APX425C or APX525C LP conversion only:
Adjust throttle screw to preliminary setting per
Table S1.
3. Start boiler as described in boiler Installation
manual and lock boiler in high fire (See
Section IX “Start-up”). If boiler does not light,
turn throttle screw in ¼ turn increments in a
counterclockwise direction until boiler fires. Do
not stop here, follow Steps 4-7.
4. Verify CO2 is within range shown in Table S2
and CO air free is less than 200 ppm. If CO2
and CO air free are within these limits, move
to Step 6 and check fan speed at high fire
operation only.
5. If CO2 is outside the window outlined in Table
S2, adjust throttle screw such that the CO2 falls
in this range while boiler is locked manually
in high fire. Turning throttle screw counterclockwise increases the CO2, while clockwise
rotation leans the mixture, reducing the CO2.
Once CO2 is within the limits in Table S2,
check CO air free again to ensure it is below
200 ppm. If CO air free is above 200 ppm turn
throttle screw clockwise in ¼ increments until
CO air free is below 200 ppm, while ensuring
CO2 remains in the range specified in Table S2.
If CO air free is still above 200 ppm, reduce fan
speed in 100 rpm increments until CO air free
is less than 200 ppm.
WARNING
Asphyxiation Hazard. Offset screw is adjusted
at the factory. DO NOT touch the offset screw if
measured low fire CO2 is within limits specified
in Table S2.
6. Lock boiler in low fire (see Section IX “System
Start-up”). Verify CO2 is within range shown in
Table S2 and CO air free is less than 200 ppm.
7. If low CO2 is too high, decrease CO2 by
turning offset screw counter-clockwise in less
than 1/8 turn increments and checking the CO2
and CO air free after each adjustment. If boiler
is equipped with 2 gas valves, offset screw
adjustments must be done to both gas valves
152
equally and simultaneously. See Figure 49 for
location of offset screw. Verify CO air free is
less than 200 ppm.
8.If low fire CO2 is too low, increase CO2 by
turning offset screw clockwise in less than
1/8 turn increments and checking the CO2 and
CO air free after each adjustment. If boiler
is equipped with 2 gas valves, offset screw
adjustments must be done to both gas valves
equally and simultaneously. See Figure 49 for
location of offset screw. Verify CO air free is
less than 200 ppm.
9. Start boiler five times at the above settings
to ensure boiler lights off without delay and
without noise. Check CO2 and CO air free to
ensure that the CO2 is within the range specified
in Table S2 and CO air free is below 200 ppm.
Be sure to replace the screw cap in the vent
adapter when combustion testing is complete.
10. Verify that the gas inlet pressure is between
the following limits with all gas appliances
(including the converted boiler) both on and
off:
• Natural Gas: 4.0 - 14.0 inches w.c.
• LP Gas: 8.0 - 14.0 inches w.c.
If inlet pressure is not within limits, adjust
before performing high altitude setup
procedure.
11.Return boiler to automatic mode. From
Operation Screen, select Automatic/Manual
Firing Rate Control >> Automatic Modulation.
Select HOME to return boiler to home screen.
Table S1: Approximate Clockwise Throttle Screw
Turns for LP Gas (Propane) Conversion
Boiler Model Approximate Throttle Screw Turns
APX425C
2¾
APX525C
3
APX625C
APX725C
N/A - Factory LP Builds
APX825C
Figure 49: Gas Valve Detail
Appendix A - Instructions for High Altitude Installations Above 2000 ft. (continued)
Table S2: Apex Altitude Adjustments
Altitude
Model
Fuel
NG
LP
NG
APX525C
LP
NG
2,001 ft
APX625C
to 4,500 ft
LP
NG
APX725C
LP
NG
APX825C
LP
NG
APX425C
LP
NG
APX525C
LP
NG
4,001 ft
APX625C
to 6,000 ft
LP
NG
APX725C
LP
NG
APX825C
LP
NG
APX425C
LP
NG
APX525C
LP
NG
6,001 ft
APX625C
to 7,800 ft
LP
NG
APX725C
LP
NG
APX825C
LP
NG
APX425C
LP
NG
APX525C
LP
NG
7,801 ft
APX625C
to 10,100 ft
LP
NG
APX725C
LP
NG
APX825C
LP
NOTE: De-rate’s per 1000 ft are approximate
**Based on minimum vent length**
APX425C
Recommended CO2 Range
8.6-9.2
9.4-10.2
8.7-9.2
9.8-10.1
8.6-9.2
9.4-9.9
8.2-8.7
9.2-9.7
8.2-9.1
9.4-10.0
8.6-9.2
9.4-10.2
8.7-9.2
9.8-10.1
8.6-9.2
9.4-9.9
8.2-8.7
9.2-9.7
8.2-9.1
9.4-10.0
8.6-9.2
9.4-10.0
8.7-9.2
No Application
8.6-9.2
9.4-9.7
8.2-8.7
9.2-9.5
No Application
9.4-9.8
8.6-9.2
9.4-9.8
8.7-9.2
No Application
8.6-9.2
9.4-9.8
8.2-8.7
No Application
No Application
9.4-9.7
Percentage Derate
(approx. per 1000 ft)
2.3%
4.1%
0.0%
1.7%
1.2%
0.0%
2.3%
4.1%
0.0%
0.0%
1.2%
0.0%
2.2%
3.6%
No Application
0.7%
1.2%
0.8%
No Application
1.4%
2.2%
3.4%
No Application
2.0%
2.0%
No Application
No Application
2.8%
153
Appendix B - Figures
Figure
Number
Page
Number
Description
Section I - Product Description, Specifications & Dimensional Data
Figure 1
6
Apex - Model APX425C
Figure 2
7
Apex - Model APX525C
Figure 3
8
Apex - Models APX625C and APX725C
Section III - Pre-Installation and Boiler Mounting
Figure 4
12
Clearances To Combustible and Non-combustible Material
Figure 5
14
Boiler Stacking with Tilted Display Panel
Section IV - Venting
Figure 6
18
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)
Figure 7
19
Direct Vent - Sidewall Standard Terminations
Figure 8
20
Direct Vent - Sidewall Snorkel Terminations
Figure 9
20
Direct Vent - Sidewall Low Profile Termination
Figure 10
21
Direct Vent - Vertical Terminations
Figure 11
21
Direct Vent - Vertical Terminations w/ Sloped Roof
Figure 12
24
Field Installation CPVC/PP/SS Vent Connector
Figure 13
24
Near-Boiler Vent/Combustion Air Piping
Figure 14
25
CPVC/PVC Expansion Loop and Offset
Figure 15
25
Wall Penetration Clearances for PVC Vent Pipe
Figure 16
26
Screen Installation
Figure 17
31
Field Installation of Polypropylene Vent Adapter
Figure 18
31
Field Installation of Polypropylene Combustion Air Adapter
Figure 19
31
Locking Band Clamp Installation, M&G DuraVent or Centrotherm InnoFlue
Figure 20
31
Alternate Locking Band Clamp Installation, M&G DuraVent
Figure 21
32
Flexible Vent in Masonry Chimney with Separate Combustion Air Intake
Figure 22
34
Field Installation of Stainless Steel Vent Adapter
Figure 23
39
Multiple Boiler Direct Vent Termination
Section V - Condensate Disposal
Figure 24
41
Condensate Trap and Drain Line
Section VI - Water Piping and Trim
Figure 25
42
Factory Supplied Piping & Trim Installation - APX425C
Figure 26
45
Factory Supplied Piping & Trim Installation - APX525C, APX625C, APX725C and APX825C
Figure 27
46
Boiler Head Loss
Figure 28
48
Near Boiler Piping - Heating Only
Figure 29
49
Near Boiler Piping - Heating Plus Indirect Water Heater
Figure 30
50
Isolation of the Boiler From Oxygenated Water with A Plate Heat Exchanger
(IWH Piped as Part of Boiler Piping)
Figure 31
51
Isolation of the Boiler From Oxygenated Water with A Plate Heat Exchanger
(IWH Piped Off System Header)
Figure 32
51
Recommended Direct Immersion Header Sensor Installation Detail
Figure 33
51
Alternate “Immersion” Type Header Sensor Installation Detail
Figure 34
52 & 53
154
Multiple Boiler Water Piping w/Domestic Hot Water Heater
Appendix B - Figures (continued)
Figure
Number
Page
Number
Description
Section VII - Gas Piping
Figure 35
56
Recommended Gas Piping
Figure 36
57
Gas Inlet Pressure Tap and Pressure Switch Location
Section VIII - Electrical
Figure 37
60
PCB Locations for Field Wiring
Figure 38
60
120 VAC Field Wiring
Figure 39
61
Low Voltage Field Wiring
Figure 40
62
Ladder Diagram
Figure 41
63
Wiring Connections Diagram
Figure 42
64
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
Figure 43
65
Modified Wiring For DHW Priority When Using Low Flow Circulator Piped Off System Header Heating (with Central Heating Zone Valves) Plus Alternately Piped Indirect Water Heater
Figure 44
66
Multiple Boiler Wiring Diagram, Internal Multiple Boiler Control Sequencer (Three Boilers Shown,
Typical Connections for up to Eight Boilers)
Figure 45
67
Multiple Boiler Wiring Diagram w/Tekmar 265 Control
Figure 46
68
Multiple Boiler Wiring Diagram w/Tekmar 264 Control
Section IX- System Start-Up
Figure 47
71
Operating Instructions
Figure 48
73
Burner Flame
Figure 49
73 & 152
Gas Valve Detail
Section X - Operation
Figure 50
80
Limit String Status Screen Showing Central Heat Demand
Figure 51
81
Home Screen
Figure 52
82
Main Menu Screen
Figure 53
84
Sequence of Operation
Figure 54
84
Home Screen Details
Figure 55
85
Status Screen Navigation
Figure 56
86
Status Screen Detail
Figure 57
87
Operations Screen
Figure 58
87
Entering Adjust Mode
Figure 59
88
Adjusting Parameters
Figure 60
90 & 151
Figure 61
97
Outdoor Reset Curve
Figure 62
107
Multiple Boiler Sequence Diagram (3 boiler system shown, typical for up to 8 boilers)
Boiler Model (Boiler Type) Decoding
Section XI - Service and Maintenance
Figure 63
119
Igniter Electrode Gap
Figure 64
120
Condensate Overflow Switch Orientation
Figure 65
121
Control Compartment Access for Stacked Boiler Installations
155
Appendix B - Figures (continued)
Figure
Number
Page
Number
Description
Section XII - Troubleshooting
Figure 66
122
Help Menu Navigation
Figure 67
124
Example Soft Lockout
Figure 68
126
Example Hard Lockout
Figure 69
129
Limit String Status
Figure 70
129
Sensors Screen with Shorted Supply Sensor
Fgure 71
133
Archives Screen
Figure 72
133
Display of Exact Data Points with Date and Time
Figure 73
133
Lockout History
Figure 74
134
Example Cycle & Run Time History
Figure 75
134
Example Alarm List
Figure 76
135
Example USB Drive File Path
Figure 77
135
Example Trend File Contents
Figure 78
136
Example Alarm File Contents
156
Appendix C - Tables
Table
Number
Page
Number
Description
Section I - Product Description, Specifications & Dimensional Data
Table 1
5
Specifications
Table 2
5
Dimensions (See Figures 1, 2, and 3)
Table 3
9
Ratings
Section III - Pre-Installation and Boiler Mounting
Table 4
10
Corrosive Combustion Air Contaminants and Sources
Table 5
11
Vent Pipe Clearances to Combustible Material
Table 6
12
Apex Boiler Model Stacking Combinations
Section IV - Venting
Table 7
16
Vent/Combustion Air Intake System Options
Table 8
17
Vent and Combustion Air Pipe Sizes and Equivalent Lengths
(Applies to All Listed Vent/Combustion Air System Options)
Table 9
17
Vent System and Combustion Air System Components Equivalent Length
(Applies to All Listed Vent/Combustion Air System Options)
Table 10
17
Vent and Combustion Air Equivalent Length Calculation Work sheet
Table 11
23
CPVC/PVC Vent & Air Intake Components Included With Boiler
Table 12
23
CPVC/PVC Vent & Air Intake Components (Installer Provided) required for Optional Horizontal
(Snorkel) Termination
Table 13
23
Components Required for Optional Ipex Profile Sidewall Termination
Table 14
23
CPVC/PVC Vent & Air Intake Components (Installer Provided) Required for
Optional Vertical Roof Termination
Table 15
25
Expansion Loop Lengths
Table 16
28
Listed Polypropylene Vent System Manufacturers
Table 17A
29
M&G DuraVent PolyPro Polypropylene Vent/Combustion Air System Components
Table 17B
29
Listed Polypropylene Pipe, Fittings and Terminations - Centrotherm Eco
Table 18
30
Listed Polypropylene Pipe, Fittings and Terminations - Z-Flex Z-Dens
Table 19
33
Thermal Solutions (Heat Fab) Vent System Components (Stainless Steel, 4 in. only)
Table 20
33
M&G Dura FasNSeal Stainless Steel Vent Systems Components, Single Wall
Table 21
34
Z-Flex, Z-Vent (SVE Series III, Z-Vent III) Stainless Steel Vent System Components, Single Wall
Section V - Condensate Disposal
Table 22
40
Maximum Condensate Flow
Section VI - Water Piping and Trim
Table 23
43
Flow Switch Paddle Application
Table 24
43
Flow Range Requirement Through Boiler
Table 25
44
Recommended Taco Circulators for 50 ft. Equivalent ft. Near Boiler Piping [Approximately 20 ft.
Straight Pipe, (4) 90° Elbows, and (2) Full Port Ball Valves]
Table 26
44
Recommended Grundfos Circulators for 50 Equivalent ft. Near Boiler Piping [Approximately 20 ft.
Straight Pipe, (4) 90° Elbows, and (2) Full Port Ball Valves]
Table 27
47
Fitting & Valve Equivalent Length
Table 28
50
Multiple Boiler Water Manifold Sizing
157
Appendix B - Tables (continued)
Table
Number
Page
Number
Description
Section VII - Gas Piping (continued)
Table 29
54
Maximum Capacity of Schedule 40 Black Pipe in CFH* (Natural Gas) For Gas Pressures of 1/2
psi (3.4 kPa) or Less
Table 30
55
Maximum Capacity of Schedule 40 Black Pipe in CFH* (LP Gas) For Gas Pressures of 1/2 psig
(3.4 kPa) or Less
Table 31
55
Equivalent Length of Standard Pipe Fittings & Valves (ft)
Table 32
55
Specific Gravity Correction Factors
Table 33
56
Min./Max. Inlet Gas Pressure Ratings
Section VIII - Electrical
Table 34
59
Boiler Current Draw
Section IX - System Start-Up
Table 35
72
Natural Gas Typical Combustion Readings (Sea Level Only)
Table 36
72
LP Gas (Propane) Typical Combustion Readings (Sea Level Only)
Table 37
74
Approximate Clockwise Throttle Screw Turns for LP Gas (Propane) Conversion
Table 38
75
Approximate Counter-Clockwise Throttle Screw Turns from Fully Closed Position, Natural Gas
Table 39
75
Approximate Counter-Clockwise Throttle Screw Turns from Fully Closed Position, LP Gas
(Propane)
Table 40
76
Field Wiring Checklist
Table 41
77
Control Parameter Checklist
Section X - Operation
Table 42
79
Order of Priority
Table 43
81
Limit String
Table 44
81
Frost Protection
Table 45
82
Setpoints
Table 46
83
Hydronic System
Table 47
83
Comfort Settings
Table 48
83
Response Speed
Table 49
83
Sequence of Operation
Table 50
96
Response Speed Adjustment Guidelines
Table 51
104 & 105
Table 52
106
Multiple Boiler Setup Procedure
Table 53
109
Energy Management System Setup Procedure
Table 54
111-115
Modbus Register List
Table 55
115
Pump Status Codes
Parameters Summary
Section XII - Troubleshooting
Table 56
124 & 125
Soft Lockout (Hold) Codes
Table 57
126 - 128
Hard Lockout Codes
Table 58
130
Sensor Fault Diagnostic Help
Table 59
130
Supply and Flue Sensor Temperature vs. Resistance, 10kOhm NTC, Beta = 3977K
Table 60
130
Return Sensor Temperature vs. Resistance, 12kOhm NTC, Beta = 3750K
158
Appendix B - Tables (continued)
Table
Number
Page
Number
Description
Section XII - Troubleshooting (continued)
Table 61
131
Outdoor Sensor Temperature vs. Resistance, 10kOhm NTC, Beta = 3435K
Table 62
131
Header Sensor Temperature vs. Resistance, 10kOhm NTC, Beta = 3950K
Table 63
132
Additional Help Menu Icons
Table 64
136
Boiler State
Appendix A - Instructions for High Altitude Installations Above 2000 ft.
Table S1
152
Approximate Clockwise Throttle Screw Turns for LP Gas (Propane) Conversion
Table S2
153
Apex Altitude Adjustments
159
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. Thermal Solutions warrants to the original
owner that its commercial grade stainless steel water boilers and parts/accessories comply at the time of manufacture with recognized hydronic industry standards and requirements
then in effect and will be free of defects in material and workmanship under normal usage for a period of one year from the date of original installation. If any part of a commercial
grade boiler or any part or accessory provided by Thermal Solutions is found to be defective in material or workmanship during this one year period, Thermal Solutions will, at its
option, repair or replace the defective part (not including labor).
HEAT EXCHANGER WARRANTIES
Thermal Solutions warrants to the original owner that the heat exchanger of its commercial grade stainless steel boilers will remain free from defects in material and workmanship
under normal usage for the time period specified in the chart below to the original owner at the original place of installation. If a claim is made under this warranty during the “No
Charge” period from the date of original installation, Thermal Solutions will, at its option, repair or replace the heat exchanger (not including labor). If a claim is made under this
warranty after the expiration of the “No Charge” period from the date of original installation, Thermal Solutions will, at its option and upon payment of the pro-rated service charge set
forth below, repair or replace the heat exchanger. The service charge applicable to a heat exchanger warranty claim is based upon the number of years the heat exchanger has been in
service and will be determined as a percentage of the retail price of the heat exchanger model involved at the time the warranty claim is made as follows:
NOTE: If the heat exchanger involved is no longer available due to product obsolescence or redesign, the value used to establish the retail price will be the published price as set forth in
Thermal Solutions Repair Parts Pricing where the heat exchanger last appeared or the current retail price of the then nearest equivalent heat exchanger, whichever is greater.
ADDITIONAL TERMS AND CONDITIONS
1. Applicability: The limited warranties set forth above are extended only to the original owner at the original place of installation within the United States and Canada. These
warranties are applicable only to boilers, parts, or accessories designated as commercial grade by Thermal Solutions and installed and used exclusively for purposes of commercial
space heating or domestic hot water generation through a heat exchanger (or a combination for such purposes) and do not apply to residential grade products or industrial uses.
2. Components Manufactured by Others: Upon expiration of the one year limited warranty on commercial grade boilers, all boiler components other than heat exchangers
manufactured by others but furnished by Thermal Solutions (such as circulator and controls) will be subject only to the manufacturer’s warranty, if any.
3. Proper Installation: The warranties extended by Thermal Solutions are conditioned upon the installation of the commercial grade boiler, parts, and accessories in strict compliance
with Thermal Solutions installation instructions. Thermal Solutions specifically disclaims liability of any kind caused by or relating to improper installation.
4. Proper Use and Maintenance: The warranties extended by Thermal Solutions conditioned upon the use of the commercial grade boiler, parts, and accessories for its intended
purposes and its maintenance accordance with Thermal Solutions recommendations and hydronics industry standards. For proper installation, use, and maintenance, see all applicable
sections of the Installation and Operating, and Service Instructions Manual furnished with the unit.
5. This warranty does not cover the following:
a. Expenses for removal or reinstallation. The owner will be responsible for the cost of removing and reinstalling the alleged defective part or its replacement and all labor and material
connected therewith, and transportation to and from Thermal Solutions.
b. Components that are part of the heating system but were not furnished by Thermal Solutions as part of the commercial boiler.
c. Improper burner set-up or adjustment, control settings, care or maintenance.
d. This warranty cannot be considered as a guarantee of workmanship of an installer connected with the installation of the Thermal Solutions boiler, or as imposing on Thermal
Solutions liability of any nature for unsatisfactory performance as a result of faulty workmanship in the installation, which liability is expressly disclaimed.
e. Boilers, parts, or accessories installed outside the 48 contiguous United States, the State of Alaska and Canada.
f. Damage to the boiler and/or property due to installation or operation of the boiler that is not in accordance with the boiler installation and operating instruction manual.
i. Any damage or failure of the boiler resulting from hard water, scale buildup or corrosion the heat exchanger. Any damage caused by improper fuels, fuel additives or contaminated
combustion air that may cause fireside corrosion and/or c logging of the burner or heat exchanger.
j. Any damage resulting from combustion air contaminated with particulate which cause clogging of the burner or combustion chamber including but not limited to sheetrock or
plasterboard particles, dirt, and dust particulate. Any damage, defects or malfunctions resulting from improper operation, maintenance, misuse, abuse, accident, negligence including
but not limited to operation with insufficient water flow, improper water level, improper water chemistry, or damage from freezing.
k. Any damage caused by water side clogging due to dirty systems, corrosion products from the system, or improperly maintained water conditions.
160
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