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
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.
104707-03 - 4/14
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........................................................................................ 10
III.
Pre-Installation and Boiler Mounting..........................................................
11
IV.
Venting......................................................................................................
15
A. General Guidelines............................................................................... 15
B. CPVC/PVC Venting.............................................................................. 20
C. Polypropylene Venting......................................................................... 26
D. Stainless Steel Venting........................................................................
29
E. Removing the Existing Boiler...............................................................
32
F. Multiple Boiler Installation Venting.......................................................
32
V.
Condensate Disposal................................................................................. 35
VI.
Water Piping and Trim............................................................................... 37
VII.
Gas Piping ...............................................................................................
51
VIII. Electrical ................................................................................................... 55
IX.
System Start-Up ....................................................................................... 67
X.
Operation......................................................................................................
75
A.Overview..............................................................................................
75
B. Supply Water Temperature Regulation................................................
76
C. Boiler Protection Features.................................................................... 77
D. Multiple Boiler Control Sequencer........................................................ 78
E. Boiler Sequence of Operation.............................................................. 79
1. Normal Operation...........................................................................
79
2. Using the Display............................................................................
80
F. Viewing Boiler Status..........................................................................
81
1. Status Screens............................................................................... 81
2. Detail Screens................................................................................
82
3. Multiple Boiler Sequencer Screens................................................
83
G. Changing Adjustable Parameters........................................................
84
1. Entering Adjust Mode....................................................................
84
2. Adjusting Parameters....................................................................
84
XI.
Service and Maintenance ........................................................................
95
XII.
Troubleshooting........................................................................................ 101
XIII. Repair Parts ............................................................................................. 106
Appendix A - Figures................................................................................
118
Appendix B - Tables.................................................................................. 120
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 1A: Specifications
Specification
Boiler Model
APX625
APX725
APX825
0-2000
0-2000
0-4500
Shipped for Natural Gas or Shipped for LP Gas
(no Field Conversion)
210
210
210
160
160
160
60
60
60
5.5
5.5
5.0
76.2
76.2
65.3
455
455
430
APX425
APX525
0-4500
0-4500
Shipped for Natural Gas, Field
Converted for LP Gas
210
210
160
160
50
50
3.4
4.2
41.8
50.8
304
350
Altitude (ft. above sea level)
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.)
* Optional 80 psi and 100 psi safety relief valves are available for all models.
Table 1B: Dimensions (See Figures 1A, 1B, 1C and 1D)
Dimension
A - Inch
(mm)
B - Inch
(mm)
C - Inch
(mm)
D - Inch
(mm)
E - Inch
(mm)
Gas Inlet F
(FPT)
Boiler Model
APX425
APX525
APX625
APX725
APX825
28-7/8
(734)
6-3/16
(157)
13-1/16
(332)
23-3/4
(602)
15-13/16
(402)
44-7/8
(1140)
22-1/8
(562)
29
(737)
39-11/16
(1008)
29-3/8
(752)
50-1/4
(1276)
50-1/4
(1276)
N/A
N/A
24
(610)
38-7/8
(987)
31-5/8
(803)
24
(610)
38-7/8
(987)
31-5/8
(803)
54-9/16
(1384)
28-3/8
(724)
34-1/4
(876)
48-1/16
(1226)
33-13/16
(864)
3/4”
3/4”
1”
1”
1”
Return G
1-1/2” (FPT)
2” (MPT)
2” (MPT)
2” (MPT)
Supply H
1-1/2” (FPT)
2” (MPT)
2” (MPT)
2” (MPT)
Condensate Drain J
Boiler Two-Pipe
CPVC/PVC Vent Connector
(Figures 1A, 1B, 1C and 1D) Inch
Factory Provided Socket End Compression Pipe Joining Clamp for 3/4” Schedule 40
PVC Pipe
4x4
6x6
6x6
6x6
5
6
Figure 1A: Apex - Model APX425
I. Product Description, Specifications and Dimensional Data (continued)
7
Figure 1B: Apex - Model APX525
I. Product Description, Specifications and Dimensional Data (continued)
8
Figure 1C: Apex - Models APX625 and APX725
I. Product Description, Specifications and Dimensional Data (continued)
9
Figure 1D: Apex - Model APX825
I. Product Description, Specifications and Dimensional Data (continued)
I. Product Description, Specifications and Dimensional Data (continued)
Table 2: Ratings
Apex Series Gas-Fired Boilers
Input (MBH)
Thermal
Efficiency (%)
Combustion
Efficiency (%)
326
94.1
94.5
413
95.0
95.0
594
516
95.0
96.0
689
599
95.0
95.0
760
661
95.0
93.0
Model
Number
Gross Output Net Ratings Water 1
(MBH)
(MBH)
Min.
Max.
APX425
80
399
375
APX525
100
500
475
APX625
125
625
APX725
145
725
APX825
160
800
Ratings shown are for installations at sea level and elevations up to 2000 ft. For elevations above 2000 ft., the boiler will naturally
derate by 2.5% for each 1000 ft. above sea level.
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.
A. Move boiler to approximate installed position.
B. Remove all crate fasteners.
C. Lift and remove outside container.
10
D. Remove boiler from cardboard positioning sleeve
on shipping skid.
E. Move boiler to its permanent location.
III. Pre-Installation and Boiler Mounting
1. Access to boiler front is provided through a door or
removable front access panel.
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.
WARNING
Asphyxiation Hazard.
Models APX425 and APX525:
Apply supplied dielectric grease to gasket inside
vent section of two-pipe 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 CSD1.
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 2 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:
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.
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. The combustion air
piping must terminate where outdoor air is available for
combustion and away from areas that may contaminate
combustion air. 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.
11
III. Pre-Installation and Boiler Mounting G. General (continued)
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.
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.
Boiler Clearances to Combustible (and NonCombustible) Material:
Models APX425 and APX525:
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 APX625, APX725 and APX825:
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:
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.
Listed Direct
Vent System
Vent Pipe
Nominal
Diameter
Minimum
Clearance to
Combustible
Material
* CPVC/PVC
4 in. (100 mm)
or
6 in.( 150 mm)
1 in. (25 mm)
Pipe Rigid
Polypropylene
Vent (or,
Flexible
Polypropylene
Liner for
Vertical
Venting only)
4 in. (100 mm)
or (110 mm)
or
6 in. (150 mm)
or (160 mm)
1 in. (25 mm)
4 in. (100 mm)
or
6 in.( 150 mm)
1 in. (25 mm)
Vent Pipe
Material
Vent
Pipe
Direction
Enclosure
Factory Standard
Two-Pipe CPVC/PVC Vent and PVC
Combustion Air Intake
Available Optional
Two-Pipe Rigid Polypropylene Vent
(or, Flexible Polypropylene Liner
for Vertical Venting only) and Rigid
Polypropylene or PVC Combustion
Air Intake
Vertical or
Horizontal
Unenclosed
at all Sides
Available Optional
Two-Pipe Stainless Steel Vent and
Galvanized Steel or PVC Combustion
Air Intake
Stainless
Steel
* Do not enclose PVC venting - use CPVC vent pipe in enclosed spaces, or to penetrate through
combustible or non-combustible walls.
12
Figure 2: Clearances To Combustible and Non-combustible Material
III. Pre-Installation and Boiler Mounting G. General (continued)
H. Boiler Stacking
1. For installations with unusually high space heating
and/or domestic hot water heating loads, where
employing 2 Apex boilers will offer the benefits
of greater operational efficiency, floor space
savings and boiler redundancy, Apex boilers may
be installed stacked maximum one boiler on top
of another. Refer to Table 3 “Apex Boiler Model
Stacking Combinations” for details.
Table 3: Apex Boiler Model Stacking
Combinations
Bottom Boiler
Top Boiler Model
Model
APX425
APX425
APX525
APX625
APX725
APX425 or APX525
APX425, APX525 or APX625
APX425, APX525, APX625 or APX725
APX425, APX525, APX625, APX725 or APX825
APX825
2. To field assemble individual Apex boilers into a
stackable configuration, use the steps below:
a. Position the bottom boiler first. Refer to Sections
II “Unpacking Boiler” and III “Pre-Installation
& Boiler Mounting” of the manual for details.
Always position higher input boiler model as
bottom boiler.
b. Each Apex boiler is factory packaged with
2 stacking boiler attachment brackets (P/N
101679-01) and the bracket mounting hardware
[six (6) self-drilling hex washer head plated #8
x ½” long screws, P/N 80860743]. Locate and
remove the brackets and the hardware. The
stacking boiler attachment bracket has three
7/32” diameter holes punched in a triangular
pattern. See Figure 3 “Stacking Boiler
Attachment Bracket Placement”.
c. Apex boiler left and right side panels have a
series of dimples at panel top and bottom. These
dimples are positioning dimples for stacking
boiler attachment bracket mounting screws. Side
panel bottom positioning dimples are evenly
spaced from boiler front and back, while side
panel top positioning dimples follow specific
pattern to compensate for Apex boiler model
variable depth.
d. Position the upper boiler on top of the bottom
boiler and align boiler front doors and sides flush
with each other.
• Place first stacking boiler attachment bracket
onto the upper boiler left side panel, at the
panel lower left corner and align bracket two
upper holes with corresponding side panel
lower dimples.
•
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. When installing stackable boiler combinations
observe the following guidelines:
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.
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.
13
III. Pre-Installation and Boiler Mounting G. General (continued)
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.
Figure 3: Stacking Boiler Attachment Bracket Placement
14
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 outdoor air for combustion. Do not obtain combustion air from within the building.
Use specified vent and combustion air pipe diameters. Do not reduce specified diameters of vent and
combustion air piping.
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 is a Direct Vent (sealed combustion)
boiler. Combustion air must be supplied directly
to the burner enclosure from outdoors and flue
gases must be vented directly outdoors.
c. The following combustion air/vent system
options are listed for use with the Apex boilers
(refer to Table 4):
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.
2. Vent/Combustion Air Piping
a. Do not exceed maximum vent/combustion air
lengths listed in Table 5. 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 6A 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 6B.
b. Maintain minimum clearance to combustible
materials. See Figure 2 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.
15
IV. Venting A. General Guidelines (continued)
Table 4: Vent/Combustion Air System Options
Approved Direct
Vent System
Vent
Material
Orientation
Termination
Standard
(through sidewall)
Horizontal
Factory Standard
Two-Pipe,
CPVC/PVC Vent and
PVC Air Intake
Optional
Snorkel
(through sidewall)
CPVC/PVC
Vertical
(through roof)
Optional
Vertical
Standard
(through sidewall)
Available Optional
Two-Pipe, Rigid
Polypropylene Vent (or
Flexible Polypropylene
Liner for Vertical
venting only) and Rigid
Polypropylene or PVC
Pipe Air Intake
Horizontal
Rigid
Polypropylene
(or Flexible
Polypropylene
Liner for vertical
Venting only)
Optional Snorkel
(through sidewall)
Optional
Vertical
Vertical
(through roof or
chimney/chase)
Standard
(through sidewall)
Horizontal
Available Optional
Two-Pipe,
Stainless Steel Vent and
PVC/Galvanized Steel
Air Intake
Optional Snorkel
(through sidewall)
Stainless Steel
Vertical
Vertical (through
roof)
Description
Figures
The system includes separate CPVC vent
pipe and PVC air intake pipe terminating
through sidewall with individual
penetrations for the vent and air intake
piping and separate terminals (tees).
Same as above but separate snorkel type
terminals.
The system includes separate CPVC vent
pipe and PVC air intake pipe terminating
through roof with individual penetrations
for the vent and air intake piping and
separate vertical terminals.
The system includes separate Rigid
Polypropylene vent pipe and Rigid
Polypropylene or PVC air intake pipe
terminating through sidewall with individual
penetrations for the vent and air intake
piping and separate terminals (tees).
Same as above but separate snorkel type
terminals.
The system includes separate Flexible
Polypropylene vent liner and Rigid
Polypropylene vent pipe combination for
venting and Rigid Polypropylene or PVC
air intake pipe terminating through roof
with individual penetrations for the vent
and air intake and separate terminals.
4, 5A, 5B
9 through 13
4, 6A, 6B
9 through 13
7 through 11
13
4, 5A, 5B
9, 12, 14
4, 6A, 6B
9, 12, 14
7 through 9
14, 15
The system includes separate stainless
steel vent pipe and PVC/galvanized
steel air intake pipe terminating through
sidewall with individual penetrations for
the vent and air intake piping and separate
terminals.
Same as above but separate snorkel type
terminals.
The system includes separate stainless
steel vent pipe and PVC/galvanized
steel air intake pipe terminating through
roof with individual penetrations for the
vent and air intake piping and separate
terminals.
Component
Table
Part
7A
7B
B.
7C
10A, 10B
10A, 10B
C.
10A, 10B
4, 5A, 5B
9, 12, 16
4, 6A, 6B
9, 12, 16
11A, 11B
D.
7 through 9
16
Table 5: Vent/Combustion Air Pipe Length – Two-Pipe Direct Vent System Options
CPVC/PVC
Polypropylene (PP) or Polypropylene (PP)/PVC
Stainless Steel/PVC or Galvanized Steel)
Boiler
Model
APX425
APX525
Combustion Air
Vent
Nominal
Pipe
Diameter
Minimum
Equivalent
Length
Maximum
Equivalent
Length
Nominal
Pipe
Diameter
Minimum
Equivalent
Length
Maximum
Equivalent
Length
4 in.
(100 mm or 110 mm)
2.5 ft.
(760 mm)
100 ft.
(30.5 m)
4 in.
(100 mm or 110 mm)
2.5 ft.
(760 mm)
100 ft.
(30.5 m)
6 in.
(150 mm or 160 mm)
2.5 ft.
(760 mm)
200 ft.
(61.0 m)
6 in.
(150 mm or 160 mm)
2.5 ft.
(760 mm)
200 ft.
(61.0 m)
APX625
APX725
APX825
16
IV. Venting A. General Guidelines (continued)
Figure 4: 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)
Table 6A: Vent System and Combustion Air System Components Equivalent Length
vs. Component Nominal Diameter
Vent or Combustion Air System
Component Description
Component Nominal Diameter
Equivalent Length for Vent or Combustion Air System Component
vs. Component Nominal Diameter
4 in. (100 mm or 110 mm)
6 in. (150 mm or 160 mm)
90° Elbow (Short Radius)
13 ft. (4.0 m)
22 ft. (6.7 m)
45° Elbow (Short Radius)
4.5 ft. (1.4 m)
7.5 ft. (2.3 m)
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 4).
17
IV. Venting A. General Guidelines (continued)
Table 6B: Vent/Combustion Air Equivalent Length Calculation Work Sheet
Combustion Air
Vent
90° Elbow(s) (Installer Supplied)
90° Elbow(s) (CPVC Supplied with Boiler)
Nominal Diameter
Quantity
Equivalent
(Pc)
Length, per Pc
4 in.
(100 mm or 110 mm)
6 in.
(150 mm or 160 mm)
Subtotal,
Equivalent
Length (A)
4 in.
(100 mm or 110 mm)
6 in.
(150 mm or 160 mm)
13 ft. (4.0 m)
22 ft. (6.7 m)
45° Elbow(s) (Installer Supplied)
Nominal Diameter
Quantity
(Pc)
4 in.
(100 mm or 110 mm)
6 in.
(150 mm or 160 mm)
Equivalent
Length, per Pc
Straight Pipe, (Installer Supplied)
Nominal Diameter
4 in.
(100 mm or 110 mm)
6 in.
(150 mm or 160 mm)
13 ft. (4.0 m)
13 ft. (4.0 m)
1
22 ft. (6.7 m)
22 ft. (6.7 m)
Nominal Diameter
Quantity
(Pc)
Equivalent Length,
per Pc
Subtotal,
Equivalent
Length (A)
13 ft. (4.0 m)
22 ft. (6.7 m)
45° Elbow(s) (Installer Supplied)
Subtotal,
Equivalent
Length (C)
1
1
* Total Equivalent Length (A+B+C) =
* Notes:
1. Calculated total equivalent length cannot exceed
maximum equivalent length shown in Table 5.
2. Vent and combustion air terminals do not count towards
total equivalent length.
3. 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
Measure length of flexible polypropylene liner = 35 ft.
Equivalent length of flexible polypropylene liner = 35 ft.
x 1.2 = 42 ft.
4. Maximum equivalent length of flexible polypropylene liner
is 48 ft. (14.6 m).
5. All elbows referenced are short radius.
18
Subtotal,
Equivalent
Length (D)
1
4 in.
(100 mm or 110 mm)
6 in.
(150 mm or 160 mm)
7.5 ft. (2.3 m)
Equivalent
Length,
ft/ft or m/m
Quantity Equivalent Length,
(Pc)
per Pc
90° Elbow(s) (Installer Supplied)
Subtotal,
Equivalent
Length (B)
4.5 ft. (1.4 m)
Quantity
Length,
ft or m
Nominal Diameter
a. Use only listed vent/combustion air terminals.
i. Horizontal Sidewall Venting: For models
APX425 and APX 525, use tee terminals for
both vent and combustion air as shown in
Figure 5A. For models APX625, APX725,
and APX825, use tee terminals or 90°
elbows for both vent and combustion air as
shown in Figure 5A or Figure 5B. Alternate
snorkel terminations are shown in Figure 6A
and Figure 6B.
ii. Vertical Roof Venting: Use straight
coupling on vent and two 90° elbows turned
downwards for combustion air as shown in
Figure 7 and Figure 8.
b. Maintain correct clearance and orientation
between vent and combustion air terminals.
Nominal Diameter
Quantity
Length,
ft or m
4 in.
(100 mm or 110 mm)
6 in.
(150 mm or 160 mm)
Equivalent Length,
ft/ft or m/m
Subtotal,
Equivalent
Length (B)
4.5 ft. (1.4 m)
7.5 ft. (2.3 m)
2.5 Ft. (760 mm) Straight Pipe, (CPVC Supplied with Boiler)
Nominal Diameter
Quantity
Length,
ft or m
4 in.
(100 mm or 110 mm)
6 in.
(150 mm or 160 mm)
2.5 ft.
(0.76 m)
2.5 ft.
(0.76 m)
Equivalent Length,
ft/ft or m/m
1
1
Subtotal,
Equivalent
Length (E)
2.5 ft.
(0.76 m)
2.5 ft.
(0.76 m)
Straight Pipe, (Installer Supplied)
Nominal Diameter
4 in.
(100 mm or 110 mm)
6 in.
(150 mm or 160 mm)
Quantity
Length,
ft
Equivalent Length,
ft/ft
Subtotal,
Equivalent
Length (C)
1
1
* Total Equivalent Length (A+B+C+D+E) =
Figure 5A: Direct Vent - Sidewall Tee Terminations
IV. Venting A. General Guidelines (continued)
Figure 5B: Direct Vent - Sidewall Elbow Terminations,
Size 625 through 825 Only
Figure 6A: Direct Vent - Optional Vent Sidewall
Snorkel Termination
Figure 6B: Direct Vent - Optional Vent and
Combustion Air Sidewall Snorkel Terminations
i.
Space centerlines of vent and combustion
air terminals minimum 12 in. (300 mm)
apart. More than 12 in. (300 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.
iii. When installed on the same wall, locate
vent terminal at same height or higher than
combustion air terminal.
iv. When using tee terminals, do not locate vent
terminal directly above air intake as dripping
condensate may freeze on and block intake.
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.
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.
j. Do not locate the vent terminal under decks or
similar structures.
k. For horizontal wall terminals, maintain minimum
clearance of at least 12 in. (300 mm) vertically
between vent terminal and eave, soffit, or roof
overhang 12 in. (300 mm) or less wide. If eave,
soffit, or roof overhang is wider than 12 in. (300
mm), increase vertical clearance to 5 ft. (1.5 m)
to avoid flue vapor condensation. Maximum
width of overhang is 3 ft. (900 mm).
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
19
IV. Venting A. General Guidelines - B. CPVC/PVC Venting (continued)
spacing is recommended to avoid frost damage
to building surfaces where vent terminations are
placed.
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
Figure 7: Direct Vent - Vertical Terminations
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
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.
Figure 8: 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.
20
IV. Venting B. CPVC/PVC Venting (continued)
NOTICE
a. Position the CPVC/PVC vent connector and
gasket onto boiler rear panel and insert vent
connector inner stainless steel vent pipe into heat
exchanger vent outlet.
b. Align vent connector plate and gasket clearance
holes with rear panel engagement holes. Then,
secure the connector and gasket to the panel with
six mounting screws.
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.
c. Attach flue temperature sensor wiring harness
(taped to boiler rear panel) female connectors to
the sensor male spade terminals. Failure to do
so will prevent boiler from starting and boiler
display will flash Red and display Limit String
Fault (see Section XII “Troubleshooting” for
details).
1.Components
a. See Table 7A for CPVC/PVC vent and
combustion air components included with boiler.
b. See Table 7B for CPVC/PVC installer provided
vent and combustion air components required for
optional horizontal snorkel terminals shown in
Figure 6B.
c. See Table 7C for CPVC/PVC installer provided
vent and combustion air components required for
optional vertical roof terminals shown in Figure
7.
NOTICE
Flue temperature sensor harness must be
connected to flue temperature sensor for the
boiler to start-up and operate properly. The
installation is not complete unless the harness
and the sensor are interconnected.
2. Field Installation of CPVC/PVC Two-Pipe
Vent System Connector
Refer to Figure 9 and following steps:
Table 7A: CPVC/PVC Vent & Air Intake Components Included With Boiler
Quantity
Vent & Air Intake Components
Schedule 40 PVC Tee
Schedule 40 PVC 90° Elbow
Stainless Steel Rodent Screen
30 in. Schedule 40 CPVC Pipe
Schedule 80 CPVC 90° Elbow
4 oz. Bottle of Transition Cement
4 oz. Bottle of Primer
CPVC/PVC Connector
CPVC/PVC Connector Gasket
Models APX425 & APX525
Standard 4 In. Termination
Vent Kit (P/N 102189-03)
includes
Models APX625, APX725 & APX825
Standard 6 In. Termination Vent Kit
(P/N (103253-01)
includes
102190-02 (Qty. 2)
N/A
102191-02 (Qty. 2)
102193-02
102192-02
N/A
103313-01 (Qty. 2)
102191-03 (Qty. 2)
103267-01
103268-01
102195-01
102194-01
4 in. x 4 in. 102183-03
4 in. x 4 in. 102185-02
6 in. x 6 in. 103270-01
6 in. x 6 in. 103248-01
Table 7B: CPVC/PVC Vent & Air Intake Components (Installer Provided) required for Optional Horizontal
(Snorkel) Termination
Vent Components
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
APX425 & APX525
Horizontal (Snorkel)
Termination, 4 in.
2
4
2
N/A
Quantity
APX625, APX725 & APX825
Horizontal (Snorkel)
Termination, 6 in.
2
4
N/A
2
21
IV. Venting B. CPVC/PVC Venting (continued)
Table 7C: CPVC/PVC Vent & Air Intake Components (Installer Provided) required for Optional Vertical
(Roof) Termination
Quantity
Vent Components
Schedule 40 PVC Coupler
Schedule 40 PVC 90° Elbow
Schedule 40 CPVC Pipe x 6 in. (150 mm) min. horizontal
run
Schedule 40 CPVC Pipe x 9 in. (230 mm) min. horizontal
run
APX425 & APX525
APX625, APX725 & APX825
Vertical (Roof) Termination, 4 in. Vertical (Roof) Termination, 6 in.
1
2
1
2
1
N/A
N/A
1
Figure 9: Field Installation of CPVC/PVC Two-Pipe Vent Connector
with Factory Installed Flue Temperature Sensor and Sensor Cap
3. Near-Boiler Vent/Combustion Air Piping
Refer to Figure 10 and the following Steps:
a. Models APX425 and APX525 only:
inside vent section of 4 in. x 4 in. two-pipe
vent connector. The grease will prevent gasket
rupture when inserting vent pipe and gasket
deterioration due to condensate exposure.
Apply supplied dielectric grease (grease pouch
attached to two-pipe vent connector) to gasket
WARNING
Asphyxiation Hazard. Models APX425 and APX525 only: Apply supplied dielectric grease to gasket
inside vent section of two-pipe 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.
Models APX625, APX725, and APX825 only: Two-pipe vent connector does not have gasketed seal.
Apply supplied red RTV silicon sealant to circumference of vent pipe before inserting pipe into vent
connector. Failure to apply the silicon could result in flue gas leaks.
22
IV. Venting B. CPVC/PVC Venting (continued)
Figure 10: Near-Boiler Vent/Combustion Air Piping
b. Models APX625, APX725, and APX825
only: 6 in. x 6 in. two-pipe connector does not
have factory installed internal sealing gaskets at
both vent and combustion air sections. Apply a
coating of supplied red RTV silicon sealant, at
least 1 in. (25 mm) wide, around circumference
of provided 6 in. Schedule 40 x 30 in. (760 mm)
long CPVC pipe.
c. 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 worm band clamp screw.
d. 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.
e. Insert Schedule 40 PVC combustion air pipe
(installer provided) into the combustion air
section of the connector with a slight twisting
motion and secure by tightening the worm band
clamp screw. For models APX625, APX725
and APX825: Apply supplied red RTV silicon
sealant, at least 1 in. (25 mm) wide, around
circumference of installer provided 6 in.
Schedule 40 PVC combustion air pipe at end to
be inserted into vent connector.
f. Clean all vent and combustion air pipe joints
with primer and secure with transition cement
(4-oz. bottles of primer and cement are
supplied with boiler inside vent carton). Follow
application instructions provided on primer and
cement bottles.
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.
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 11
and Table 8.
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.
5. Horizontal Sidewall Termination
a. Standard Two-Pipe Termination
See Figures 5A and 5B.
23
IV. Venting B. CPVC/PVC Venting (continued)
Table 8: Expansion Loop Lengths
Nominal
Pipe
Dia. (In.)
4
6
i.
24
Length of
Straight Run
ft.
m
Loop Length
“L”
in.
mm
20
6.1
60
1520
30
9.1
74
1880
40
12
85
2159
50
15
95
2413
60
18
104
2642
20
6.1
73
1850
30
9.1
90
2290
40
12
103
2620
50
15
116
2950
60
18
127
3230
Figure 11: CPVC/PVC Expansion Loop and Offset
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.
• PVC vent pipe may not be used
to penetrate combustible or noncombustible walls unless all following
three conditions are met simultaneously
(see Figure 12):
- 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 12 is maintained around outside of the vent pipe to provide air circulation
Figure 12: Wall Penetration Clearances
for PVC Vent Pipe
• If above three conditions cannot be
met simultaneously when penetrating
a combustible wall, use a single wall
thimble [Thermal Solutions part numbers
102181-01 (4 in.) and 103419-01 (6 in.)].
• Thimble use is optional for noncombustible wall.
• Insert thimble into cut opening from
outside. Secure thimble outside flange to
wall with nails or screws and seal ID and
OD with sealant material.
IV. Venting B. CPVC/PVC Venting (continued)
• When thimble is not used for noncombustible wall, size and cut wall
opening such that a minimal clearance is
obtained and to allow easy insertion of
vent pipe.
• Apply sealant between vent pipe and
thimble or wall opening to provide
weather-tight seal. Sealant should not
restrain the expansion of the vent pipe.
• Install rodent screen and vent terminal
(supplied with boiler). See Figure 13 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 rodent screen and combustion
air terminal (supplied with boiler). See
Figure 13 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 Figures 6A and 6B.
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
Exterior run to be included in equivalent vent/
combustion air lengths.
i.
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 6A.
• At top of vent pipe length install another
PVC 90° elbow so that elbow leg is
opposite the building’s exterior surface.
• Install rodent screen and vent terminal
(supplied with boiler), see Figure 13 for
appropriate configuration.
• Brace exterior piping if required.
Figure 13: Rodent Screen Installation
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 6B.
• At top of air pipe length install another
PVC 90° elbow so that elbow leg is
opposite the building’s exterior surface.
• Install rodent screen and combustion
air terminal (supplied with boiler). See
Figure 13 for appropriate configuration.
• Brace exterior piping if required.
6. Vertical Roof Termination
a. Standard Two-Pipe Termination
See Figures 7 and 8.
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 7 and
8.
- 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.
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 25
IV. Venting B. CPVC/PVC Venting - C. Polypropylene Venting (continued)
Sealant or equivalent between vent pipe and storm collar to provide weather-tight seal.
• Install rodent screen and vent terminal
(supplied with boiler). See Figure 13 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 rodent screen and combustion
air terminal (supplied with boiler). See
Figure 13 for appropriate configuration.
• Brace exterior piping if required.
C. Polypropylene Venting
WARNING
Asphyxiation Hazard. Follow these
instructions and the installation instructions
included by the original polypropylene
venting component manufacturers, M&G/
DuraVent or Centrotherm, 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 M&G/
DuraVent or Centrotherm 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.
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
a. Listed polypropylene vent system manufacturers
are shown in Table 9. It is the responsibility of
the installing contractor to procure polypropylene
vent system pipe and related components.
i. M&G/DuraVent PolyPro Single Wall Rigid
Vent and PolyPro Flex Flexible Vent comply
with the requirements of ULC-S636-08
‘Standard for Type BH Gas Venting
Systems’.
Table 9: Listed Polypropylene Vent System
Manufacturers
Make
Model
PolyPro Single Wall Rigid Vent
M&G/
PolyPro Flex Flexible Vent (APX425 and
DuraVent
APX525)
InnoFlue SW Rigid Vent
Centrotherm
Eco Systems Flex Flexible Vent (APX425 and
APX525)
26
IV. Venting C. Polypropylene Venting
ii. Centrotherm Eco Systems InnoFlue SW
Rigid Vent and Flex Flexible Vent comply
with the requirements of UL 1738 ‘Standard
for Safety for Venting Systems’ and
ULC-S636-08 ‘Standard for Type BH Gas
Venting Systems’.
b. See Table 10A for specific M&G Duravent
components.
c. See Table 10B for specific Centrotherm Eco
Systems components.
f. Do not install PVC to PP adapter at the lower
combustion air supply port of the two-pipe vent
system connector when using PVC pipe for
combustion air supply to boiler.
3. System Assembly
WARNING
Asphyxiation Hazard. Vent systems made by
M&G/DuraVent and Centrotherm Eco Systems
rely on gaskets for proper sealing. When these
vent systems are used, take the following
precautions:
2. Field Installation of CPVC/PVC Two-
Pipe Vent System Connector and PVC to Polypropylene Adapter
a. Install CPVC/PVC two-pipe vent system
connector. Follow instructions in “2. Field
Installation of CPVC/PVC Two-Pipe Vent
System Connector” under “B. CPVC/PVC
Venting.” See Figures 9 and 14.
• 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.
b. Models APX425 and APX525 only: Apply
provided dielectric grease (grease pouch taped to
the vent system connector) all around to the vent
or air connection inner red silicon gasket.
• 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.
c. Models APX625, APX725 and APX825
only: Apply a coating of supplied red RTV
silicone sealant, at least 1 in. (25 mm) wide,
around circumference of PVC to PP adapter male
end. d. Push and twist PVC to PP adapter into two-pipe
vent system connector vent or combustion air
supply port until bottomed out.
e. Tighten the worm band clamp screw to secure
PVC to PP adapter.
• 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.
Table 10A: Listed Polypropylene Pipe, Fittings and Terminations - M&G/DuraVent
Boiler
Model
APX425
APX525
APX625
APX725
APX825
Male Boiler Adapter,
PVC to PP
M&G / DuraVent Part Numbers/Sizes
Rigid Pipe
Flex Pipe
Pipe Joint
Side Wall
Nominal Dia.
Nominal Dia.
Locking Band Termination Tee
Chimney Kit for
Venting Only
4PPS-04PVCM-4PPF
4 in.
(100 mm)
4 in.
(100 mm)
43PPS-LB
43PPS-TB
4PPS-FK
6PPS-06PVCM-6PPF
6 in.
(150 mm)
N/A
6PPS-LBC
6PPS-E90B
N/A
Table 10B: Listed Polypropylene Pipe, Fittings and Terminations - Centrotherm Eco
Boiler
Model
APX425
APX525
APX625
APX725
APX825
Male Boiler Adapter,
PVC to PP
Centrotherm Eco Part Numbers/Sizes
Rigid Pipe
Flex Pipe
Pipe Joint
Side Wall
Nominal Dia.
Nominal Dia.
Locking Band
Termination Tee
ISAA0404
ISSAL0404
4 in.
(110 mm)
ISAA0606
ISSAL0606
6 in.
(160 mm)
4 in.
(110 mm)
N/A
Chimney Kit for
Venting Only
IANS04
ISTT0420
IFCK0425
and
IFCK0435
IANS06
ISTT0620
N/A
27
IV. Venting C. Polypropylene Venting (continued)
Figure 14: Vent System Field Modification to Install
PVC to PP Adapter (M&G/DuraVent Shown)
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.
NOTICE
The venting system must be free to expand
and contract and supported in accordance
with installation instructions included by the
original polypropylene venting component
manufacturers, M&G/DuraVent or Centrotherm,
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. 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.
NOTICE
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).
28
a. Models APX425 and APX525 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 15 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
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.
IV. Venting C. Polypropylene Venting - D. Stainless Steel Venting (continued)
Venting of Other Appliances (or Fireplace)
into Chase or Adjacent Flues Prohibited!
Figure 15: Flexible Vent in Masonry Chimney
with Separate Combustion Air Intake
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
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 APX425 and APX525,
Thermal Solutions offers size 4 in. vent pipe
and fittings shown in Table 11A. It is the
responsibility of the installing contractor to
procure stainless steel vent system pipe and
related components.
b. Alternate listed stainless steel vent system
manufacturers and components are shown in
Table 11B.
29
IV. Venting D. Stainless Steel Venting (continued)
Table 11A: Thermal Solutions Vent System
Components (Stainless Steel, 4 in. only)
Part
Numbers
APX425 and
APX525
Vent System
Component
Equivalent
Length of Pipe
4 In. Vent
SS Vent Kit
102501-02
Horizontal Vent Terminal
(Included in Kit)
PVC to SS Vent Adapter
(Included In Kit)
Vertical Vent Terminal
Pipe x 1 ft. (0.3 m)
Pipe x 3 ft. (0.9 m)
Pipe x 5 ft. (1.5 m)
8116313
Figure 16: Field Installation of Two-Pipe Vent
System Adapter for Stainless Steel
N/A
102220-01
102680-02
100176-01
100177-01
100178-01
2. Field Installation of CPVC/PVC Two-Pipe
Vent System Connector and PVC to Stainless
Steel Adapter
1 ft. (0.3 m)
3 ft. (0.9 m)
5 ft. (1.5 m)
Equal to
Installed Length
1.06 to 1.64 ft.
(0.3 m to 0.5 m)
Pipe x Adjustable
100179-01
90° Elbow
100180-01
8 ft. (2.4 m)
45° Elbow
100181-01
4.5 ft. (1.4 m)
Horizontal Drain Tee
Vertical Drain Tee
Single Wall Thimble
100182-01
100183-01
100184-01
2 ft. (0.6 m)
7.5 ft. (2.3 m)
N/A
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.
a. Install CPVC/PVC two-pipe vent system
connector. Follow instructions in “2. Field
Installation of CPVC/PVC Two-Pipe Vent
System Connector” under “B. CPVC/PVC
Venting.” See also Figures 9 and 16.
b. Models APX425 and APX525 only: Apply
provided dielectric grease (grease pouch taped to
the vent system connector) all around to the vent
or air connection inner red silicon gasket.
c. Models APX625, APX725 and APX825
only: Apply a coating of supplied red RTV
silicone sealant, at least 1 in. (25 mm) wide,
around circumference of PVC to stainless steel
adapter male end.
d. Push and twist PVC to stainless steel adapter
into two-pipe vent system connector vent or
combustion air supply port until bottomed out.
See Figure 16.
e. Tighten the worm band clamp screw to secure
PVC to stainless steel adapter.
f. Do not install PVC to stainless steel adapter
at the lower combustion air supply port of the
two-pipe vent system connector when using PVC
pipe for combustion air supply to boiler.
Table 11B: Alternate Vent Systems and Vent Components (Stainless Steel)
Manufacturer
M&G/DuraVent
Z-Flex
Vent
System
FasNseal
SVE Series III
(“Z-Vent III”)
Nominal Dia.
PVC to SS
Adapter
Wall Thimbles
Horizontal
Termination
Vertical
Termination
4 in.
(100 mm)
810005231
FSWT4
Tee: FSTT4
FSBS4
6 in.
(150 mm)
810005545
FSWT6
Tee: FSTT6
FSBS6
4 in.
(100 mm)
2SVSTTA04.5
2SVSWTF04
Tee: 2SVSTTX04
2SVSTPX04
6 in.
(150 mm)
2SVSTTA06.5
2SVSWTF06
Tee: 2SVSTTX06
2SVSTPX06
NOTE: See vent system manufacturer’s literature for other part numbers that are required such as straight pipe, elbows, firestops
and vent supports.
30
IV. Venting D. Stainless Steel Venting (continued)
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.
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
4. Horizontal Sidewall Vent Termination
a. Standard Two-Pipe Termination
See Figures 5A and 5B.
i.
Vent Termination
• Use a stainless steel tee in the upright
position.
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 tee in the upright position. Tee
should protrude the same distance from
the wall as the exhaust terminal as shown
in Figure 5A.
• Install a rodent screen (not supplied) 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 Figures 6A and 6B.
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 6A.
• 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.
31
IV. Venting D. Stainless Steel Venting - E. Removing the Existing Boiler - F. Multiple Boiler Installation Venting (continued)
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 6B.
• At top of vent pipe length install another
90° elbow so that the elbow leg is
opposite the building’s exterior surface.
• Install rodent screen (not supplied) and
horizontal vent terminal.
• Brace exterior piping if required.
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.
5. Vertical Vent Termination
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.
a. Standard Two-Pipe Termination
See Figures 7 and 8.
i.
Vent Termination
• Use the terminal supplied by the vent
system manufacturer shown in Table
11B. 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 7.
• Install rodent screen (not supplied) 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. 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
32
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
IV. Venting F. Multiple Boiler Installation Venting (continued)
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.
F. Multiple Boiler Installation Venting
1. Vent Piping and Terminations
a. Multiple boiler vent terminations are shown in
Figure 17.
b. Each individual boiler must have its own vent
pipe and vent terminal. Refer to Paragraphs A
through E (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 5.
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.
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 17.
b. Each individual boiler must have own
combustion air pipe and terminal. Refer to
Paragraphs A through E (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 5.
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.
33
34
Figure 17: Multiple Boiler Direct Vent Termination
IV. Venting F. 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 1A, 1B, 1C, 1D and
18.
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 18.
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 11C “Maximum Condensate Flow”.
Table 11C: Maximum Condensate Flow
Boiler
Model
*Maximum Condensate Flow,
GPH
APX425
4.5
APX525
5.6
APX625
7.0
APX725
8.1
APX825
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.
35
V. Condensate Disposal (continued)
Figure 18: 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.
36
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.
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
Apex boilers have factory supplied Miscellaneous Parts
Carton, which includes packaged flow switch with two
boiler-specific paddles, supply piping components, gas
piping components, temperature & pressure gauge,
safety relief valve and drain valve. See Figure 19A, 19B
or 19C “Factory Supplied Piping and Trim Installation”.
Install these components prior to connecting boiler
to system piping as follows:
Boiler
Model
APX425
APX525
APX625
APX725
APX825
Miscellaneous
Parts Carton
102942-05
1. Models APX425 and APX525 (see Figure
19A “Factory Supplied Piping and Trim
Installation - APX425 and APX525”)
a. Locate and remove ¾ in. NPT x close black
nipple, ¾ in. NPT x 12 in. black nipple, ¾ in.
NPT black tee, ¾ in. FPT x ¾ in. FPT safety
relief valve and ¾ in. NPT drain valve.
b. Install close nipple into tee branch. Then, screw
the assembly into boiler left side front ¾ in.
FPT tapping, making sure tee run outlets are in
vertical plane and parallel to boiler side.
c. Install the ¾ in. NPT x 12 in. black nipple into
tee run top outlet.
d. Mount ¾ in. FPT x ¾ in. FPT safety relief valve
onto 12 in. nipple.
104520-01
103259-02
Figure 19A: Factory Supplied Piping and Trim Installation - APX425 and APX525
37
VI. Water Piping and Trim A. Factory Supplied Piping and Trim (continued)
e. Install drain valve into tee bottom outlet.
f. Locate and remove (2) 1½ in. NPT x 2 in. long
black nipples, 1½ in. x 1½ in. x ¾ in. NPT
black tee, 1½ in. x 1½ in. x 1 in. NPT black tee,
packaged flow switch with paddles, ¾ in. x ¼ in.
NPT black reducing bushing and temperature &
pressure gauge.
g. Mount (1) 1½ in. NPT 2 in. long nipple into
1½ in. FPT boiler supply tapping (see Figures
1A and 1B). Then, install 1½ in. x 1½ in. x ¾
in. NPT tee onto the nipple, making sure ¾ in.
branch outlet is in horizontal plane and facing
the boiler front.
h. Install ¾ in. x ¼ in. NPT black reducing bushing
into the tee branch. Then, put in temperature &
pressure gauge.
i. Install second 1½ in. NPT x 2 in. long nipple into
1½ in. x 1½ in. x ¾ in. NPT tee run.
j. Mount 1½ in. x 1½ in. x 1 in. NPT black tee onto
the nipple, making sure tee 1 in. NPT branch
outlet is in upright position.
k. Remove flow switch and paddles from packaging
carton. Also see/follow Taco Instruction Sheet
for Flow Switch Kit (supplied with the flow
switch) for specific details.
l. Select the paddle stamped “1” for the APX425
and APX525.
m.Attach paddle to flow switch stem using supplied
machine screw.
38
n. Apply pipe dope to the switch-threaded brassbushing end. Then, mount the switch threaded
end with the attached paddle into 1-1/2 in. x
1-1/2 in. x 1 in. NPT tee branch and tighten
such that distance between bottom of switch
housing and top of tee branch is approximately
1-11/16 in. (43 mm). Insure the switch paddle
is positioned perpendicular to the flow direction
for the best flow sensitivity. Do not tighten the
switch by grasping the switch enclosure. Use the
wrenching flats on the bushing only. The turning
radius required for the switch mounting is 3 in.
(80 mm).
o. For flow switch wiring refer to Section VIII
“Electrical” of these instructions.
2. Models APX625 and APX725 (see Figure
19B, “Factory Supplied Piping and Trim
Installation – APX625 and APX725”)
a. Locate 2 in. x 2 in. x 3/4 in. NPT black tee, 3/4
in. NPT x close black nipple, and 3/4 in. NPT
black tee. Install close nipple in branch of 2 in.
x 2 in. x 3/4 in. NPT tee. Install branch of 3/4 in.
NPT tee onto other end of close nipple. Install
2 in. x 2 in. x 3/4 in. NPT tee onto 2 in. MPT
supply connection at front of boiler, making
sure branch of 2 in. x 2 in. x 3/4 in. NPT tee is
oriented towards front of boiler and run of 3/4”
NPT tee is oriented vertically.
Figure 19B: Factory Supplied Piping and Trim Installation - APX625 and APX725
VI. Water Piping and Trim A. Factory Supplied Piping and Trim (continued)
b. Locate 3/4 in. NPT x 12 in. black nipple, 3/4
in. FPT x 1 in. FPT safety relief valve, and 3/4
in. NPT drain valve. Install nipple in top run
of 3/4 in. NPT tee connected to supply in Step
a. Mount safety relief valve onto nipple. Install
drain valve in bottom run of 3/4 in. NPT tee
connected to Supply in Step a.
c. Locate 2 in. x 2 in. x 1/2 in. NPT black tee, one 2
in. NPT x 2-1/2 in. black nipple, and 1/2 in. NPT
temperature and pressure gage. Install nipple
into 2 in. x 2 in. x 3/4 in. NPT tee installed in
Step a. Install 2 in. x 2 in. x 1/2 in. NPT tee onto
nipple, making sure branch is oriented towards
front of boiler. Then, install temperature and
pressure gage onto tee branch.
d. Locate 2 in. x 2 in. x 1 in. NPT black tee and
second 2 in. NPT x 2-1/2 in. black nipple.
Install nipple into 2 in. x 2 in. x 1/2 in. NPT
tee installed in Step c. Install 2 in. x 2 in. x 1
in. NPT tee onto nipple, making sure branch is
oriented upward.
e. Locate flow switch kit. Remove flow switch
and paddles from packaging carton. See Taco
Instruction Sheet for Flow Switch Kit (supplied
with flow switch) for specific details.
f. For APX625, select paddle stamped “3”.
g. For APX725, select paddle stamped “1”.
h. Attach paddle to flow switch stem using supplied
machine screw.
i. Apply pipe dope to flow switch at threaded brassbushing end. Then, mount the switch threaded
end with attached paddle into 2 in. x 2 in. x 1 in.
NPT tee branch and tighten such that distance
between bottom of switch housing and top of tee
branch is approximately 1-11/16 in. (43 mm).
Insure switch paddle is positioned perpendicular
to flow direction for best flow sensitivity. Do
not tighten switch by grasping switch enclosure.
Use wrenching flats on bushing only. The
turning radius required for switch mounting is
3 in. (80 mm).
j. For flow switch wiring, refer to Section VIII
“Electrical” of these instructions.
3. Model APX825 (see Figure 19C “Factory
Supplied Piping and Trim Installation APX825”)
a. Locate and remove ¾ in. NPT x close black
nipple, ¾ in. NPT x 12 in. black nipple, ¾ in.
NPT black tee, ¾ in. FPT x 1 in. FPT safety
relief valve and ¾ in. NPT drain valve.
Figure 19C: Factory Supplied Piping and Trim Installation - APX825
39
VI. Water Piping and Trim A. Factory Supplied Piping and Trim (continued)
h. Install temperature & pressure gauge into the tee
branch.
i. Install second 2 in. NPT x 2½ in. long nipple into
2 in. x 2 in. x 1/2 in. NPT tee run.
j. Mount 2 in. x 2 in. x 1 in. NPT black tee onto the
nipple, making sure tee 1 in. NPT branch outlet
is oriented upward.
k. Remove flow switch and paddles from packaging
carton. Also see/follow Taco Instruction Sheet
for Flow Switch Kit (supplied with flow switch)
for specific details.
l. Select paddle stamped “1” for APX825.
m. Attach paddle to flow switch stem using supplied
machine screw.
n. Apply pipe dope to the switch-threaded brassbushing end. Then, mount the switch threaded
end with the attached paddle into 2 in. x 2 in.
x 1 in. NPT tee branch and tighten such that
distance between bottom of switch housing and
top of tee branch is approximately 1-11/16 in.
(43 mm). Insure the switch paddle is positioned
b. Install close nipple into tee branch. Then, screw
the assembly into boiler left side ¾ in. front
tapping, making sure tee run outlet is in vertical
plane and parallel to boiler side.
c. Install the ¾ in. NPT x 12 in. black nipple into
tee top run outlet.
d. Mount ¾ in. FPT x 1 in. FPT safety relief valve
onto 12 in. nipple.
e. Install drain valve into tee bottom run outlet.
f. Locate and remove 2 in. NPT steel coupling,
(2) 2 in. NPT x 2-1/2 in. long black nipples, 2
in. x 2 in. x ½ in. NPT black tee, 2 in. x 2 in. x
1 in. NPT black tee, packaged flow switch with
paddles, and temperature & pressure gauge.
g. Mount 2 in. NPT coupling onto 2 in. MPT boiler
supply tapping (see Figure 1C). Then, install 2
in. NPT x 2-1/2 in. long black nipple into the
coupling outlet. Attach 2 in. x 2 in. x ½ in. tee
onto the nipple opposite end, making sure ½ in.
branch outlet is in horizontal plane and facing
the boiler front.
Table 12: Flow Range Requirement Through Boiler
Boiler
Model
APX425
APX525
APX625
APX725
APX825
Supply
Return
Connection Connection
(in.)
(in.)
1-1/2
1-1/2
2
2
2
1-1/2
1-1/2
2
2
2
ΔT = 35°F
ΔT = 30°F
ΔT = 25°F
Minimum
Boiler Required
Boiler
Required
Boiler
Required
Head
Flow
Head Loss
Flow
Head Loss
Flow (GPM) Loss (ft.) (GPM)
(ft.)
(GPM)
(ft.)
21.5
27.1
33.9
39.4
43.4
6.1
6.9
4.7
6.0
12.1
25.1
31.7
39.6
45.9
50.7
7.9
8.9
6.1
7.9
15.5
30.2
38.0
47.5
55.1
60.8
10.8
12.1
8.4
10.9
20.9
ΔT = 20°F
Maximum
Boiler
Required
Head
Flow
Loss (ft.)
(GPM)
37.7
15.9
47.5
17.6
59.4
12.4
68.9
16.1
76.0
30.0
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 2. See also Tables 13 A and 13B for near boiler piping sizing.
Using boiler antifreeze will result in increased fluid density and may require larger circulators.
Boiler Head Loss
30
825
25
20
Head
Loss 15
(ft.)
425
525
625/725
10
5
0
0
40
10
20
30
40
50
Water Flow Rate (GPM)
60
70
80
VI. Water Piping and Trim B. Piping System To Be Employed (continued).
perpendicular to the flow direction for the
best flow sensitivity. Do not tighten the switch
by grasping the switch enclosure. Use the
wrenching flats on the bushing only. The turning
radius required for the switch mounting is 3 in.
(80 mm).
o. For flow switch wiring refer to Section VIII
“Electrical” of these instructions.
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 20 psi (140 kPa). Proper operation of the Apex
boiler requires that the water flow through the boiler
remain within the limits shown in Table 12 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.
a. The flow rate through the isolated near-boiler
loop is maintained by installer supplied
boiler circulator. See Tables 13A and 13B 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.
i. Space heating only - refer to Tables 13A and
13B and Figure 20 “Near Boiler Piping Heating Only” as applicable.
ii. Space heating plus indirect water heater(s)
– refer to Tables 13A and 13B and Figure 21
“Near Boiler Piping - Heating Plus Indirect
Water Heater” as applicable.
iii. If piping indirect water heater off boiler
(see Figure 22A), be sure that indirect water
heater and domestic hot water circulator are
sized to maintain flow through boiler within
limits shown in Table 12.
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 12.
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.
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 Figures
19A, 19B or 19C “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 APX425
and APX525 and 60 psi (410 kPa) on APX625,
APX725 and APX825. 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.
41
42
1½
2
2
2
APX525
APX625
APX725
APX825
2½
2
2
2
2
43.4
39.4
33.9
27.1
21.5
12.6
7.1
5.5
7.4
6.4
Boiler &
Piping
Head Loss
(ft.)
ΔT=35°F
2400-45
50.7
45.9
39.6
2400-40
31.7
0013
25.1
Flow
(GPM)
0012 or
2400-20
0014
Circulator
Model
16.3
9.4
7.2
9.6
8.4
Boiler &
Piping
Head Loss
(ft.)
ΔT=30°F
2400-50
2400-60
2400-40
2400-20
0013
Circulator
Model
60.8
55.1
47.5
38.0
30.2
21.9
12.9
9.9
13.1
11.5
Boiler &
Flow
Piping
(GPM) Head Loss
(ft.)
ΔT=25°F
1915
2400-65
2400-60
2400-30
2400-20
Circulator
Model
1½
1½
2
2
2
APX425
APX525
APX625
APX725
APX825
2½
2
2
2
2
Supply
Near
Boiler
& Return
Boiler
Model Connection Pipe Size
(in.)
(in.)
43.4
39.4
33.9
27.1
21.5
Flow
(GPM)
12.6
7.1
5.5
7.4
6.4
Boiler &
Piping
Head Loss
(ft.)
25.1
31.7
39.6
45.9
50.7
UPS43-44FC,
Spd. 3 or
UP26-99F
UPS43-44FC,
Spd. 3
UPS43-100F,
Spd. 2
UPS43-100F,
Spd. 3
Circulator
Model
16.3
9.4
7.2
9.6
8.4
UPS40-80/4,
Spd. 3
60.8
55.1
UPS43-100F,
Spd. 3
38.0
30.2
47.5
UPS26-150F,
Spd. 2
UP26-99F
Circulator
Model
21.9
12.9
9.9
13.1
11.5
76.0
68.9
UPS40-80/4,
Spd. 3
UP43-110F
59.4
UPS43-100F,
Spd. 3
47.5
37.7
UPS43-100F,
Spd. 2
UPS43-100F,
Spd. 3
Flow
(GPM)
76.0
68.9
59.4
47.5
37.7
Flow
(GPM)
Circulator
Model
ΔT=25°F
Boiler &
Flow
Piping
(GPM) Head Loss
(ft.)
UPS43-100F,
Spd. 2
ΔT=30°F
Boiler &
Flow
Piping
(GPM) Head Loss
(ft.)
UP26-64F
ΔT=35°F
Table 13B: 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
APX425
Boiler
Model
Supply
Near Boiler
& Return
Pipe Size
Flow
Connection
(in.)
(GPM)
(in.)
Table 13A: 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]
31.6
19.1
14.7
19.1
16.9
Boiler &
Piping
Head Loss
(ft.)
ΔT=20°F
31.6
19.1
14.7
19.1
16.9
UPS40-240/2,
Spd. 3
UP43-110F
UPS40-80/4,
Spd. 3
UP43-110F
UPS43-100F,
Spd. 3
Circulator
Model
1935
2400-70
2400-70
2400-50
2400-45
Boiler &
Piping
Circulator
Head Loss
Model
(ft.)
ΔT=20°F
VI. Water Piping and Trim C. Standard Installation Requirements (continued)
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
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.
4. Expansion Tank (Required) – If this boiler is
replacing an existing boiler with no other changes
in the system, the old expansion tank can generally
Table 14: 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
be reused. If the expansion tank must be replaced,
consult the expansion tank manufacturer’s literature
for proper sizing.
5. Fill Valve (Required) – Either manual
(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 (Required by some
Codes) - This control is required by ASME CSD-1
and some other codes. Install the high limit in the
boiler supply piping just above the boiler with no
intervening valves. Set the manual reset high limit
to 210°F. Follow Section VIII “Electrical” to wire
the high limit.
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.
9. Flow Control Valve (Strongly
Recommended) – The flow control valve prevents
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.
Table 14: Fitting and Valve Equivalent Length
(cont’d)
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 14 is provided as reference to assist in piping design and specifies equivalent length of typical piping
fittings and valves.
43
VI. Water Piping and Trim C. Standard Installation Requirements (continued)
10. Isolation Valves (Strongly Recommended) –
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 19A, 19B or 19C
“Factory Supplied Piping and Trim Installation”.
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 20 psi (140 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.
44
45
Figure 20: Near Boiler Piping - Heating Only
VI. Water Piping and Trim C. Standard Installation Requirements (continued)
46
Figure 21: Near Boiler Piping - Heating Plus Indirect Water Heater
VI. Water Piping and Trim C. Standard Installation Requirements (continued)
VI. Water Piping and Trim D. Special Situation Piping Installation Requirements (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 22A and
22B. 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 15: Multiple Boiler Water Manifold Sizing
Boiler Model
APX425
APX525
APX625
APX725
APX825
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 22A: Isolation of the Boiler From Oxygenated Water with A Plate Heat Exchanger
(IWH Piped as Part of Boiler Piping)
47
VI. Water Piping and Trim E. Multiple Boiler Installation Water Piping (continued)
Figure 22B: Isolation of the Boiler From Oxygenated Water with A Plate Heat Exchanger
(IWH Piped Off System Header)
E. Multiple Boiler Installation Water Piping - See
Table 15 and Figures 22B 23A and 23B.
1. Refer to this Section of this manual for:
a. Installation of factory supplied piping and trim
components for an individual module (boiler).
b. Regarding an individual module (boiler) piping
system specific details.
c. Selection criteria for individual module (boiler)
space heating and/or DHW circulators.
48
2. 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 Figures 23A and 23B.
49
Figure 23A: 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 E. Multiple Boiler Installation Water Piping (continued)
50
Figure 23B: 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 E. Multiple Boiler Installation (continued)
VII. Gas Piping
1. Allowable pressure drop from point of
delivery to boiler. Maximum allowable system
WARNING
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.
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 16A (natural gas) or 16B (LP gas)
for maximum capacity of Schedule 40 pipe. Table
17 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 16A and gas with a specific
gravity of 1.5 can be sized from Table 16B, unless
authority having jurisdiction specifies a gravity
factor be applied. For other specific gravity, apply
gravity factor from Table 18. 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 16A: 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 13.8 in wc (3.4 kPa)or less; 0.3 in wc (0.07 kPa) Pressure Drop
Nominal Pipe
Size, In.
Inside
Diameter, In.
10
20
30
40
Length of Pipe, Ft.
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
1056
726
583
499
442
400
368
343
322
304
1½
1.610
1582
1087
873
747
662
600
552
514
482
455
2
2.067
3046
2094
1681
1439
1275
1156
1063
989
928
877
2½
2.469
4856
3337
2680
2294
2033
1842
1695
1576
1479
1397
3
3.068
8584
5900
4738
4055
3594
3256
2996
2787
2615
2470
Inlet Pressure 13.8 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
1392
957
768
657
583
528
486
452
424
400
1½
1.610
2085
1433
1151
985
873
791
728
677
635
600
2
2.067
4016
2760
2217
1897
1681
1523
1402
1304
1223
1156
2½
2.469
6401
4400
3533
3024
2680
2428
2234
2078
1950
1842
3
3.068
11316
7778
6246
5345
4738
4293
3949
3674
3447
3256
* 1 CFH of Natural Gas is approximately equal to 1 MBH; contact your gas supplier for the actual heating value of your
gas.
51
VII. Gas Piping (continued)
B. Connect boiler gas valve to gas supply
system.
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.
Table 16B: 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
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.
10
20
30
40
Length of Pipe, Ft.
50
60
70
80
90
100
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 17: Equivalent Lengths of Standard Pipe Fittings & Valves (ft)
Nominal
Pipe Size,
Inc.
52
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
VII. Gas Piping (continued)
Table 18: Specific Gravity Correction Factors
Specific
Gravity
Correction
Factor
Specific
Gravity
Correction
Factor
0.60
1.00
0.90
0.82
0.65
0.96
1.00
0.78
0.70
0.93
1.10
0.74
0.75
0.90
1.20
0.71
0.80
0.87
1.30
0.68
0.85
0.81
1.40
0.66
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.
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
APX425
APX525
APX625
APX725
APX825
Miscellaneous
Parts Carton
102942-05
104520-01
103259-02
Models APX425 and APX525
a. Locate and remove the ¾ in. NPT x 6 in. long
black nipple and ¾ in. NPT external gas shutoff
valve (required).
b. Model APX525 boiler has ¾ in. NPT x 12 in.
long black nipple and left side panel grommet
factory installed (disregard the supplied
¾ in. NPT x 6 in. long black nipple in the
miscellaneous parts carton).
c. Mount the ¾ in. NPT external gas shutoff valve
onto the nipple threaded end outside of the jacket
left side panel.
Figure 24: Recommended Gas Piping
d. Install sediment trap, ground-joint union and
manual shut-off valve upstream of mounted
factory supplied manual shut-off valve. See
Figure 24 “ Recommended Gas Piping ”.
Models APX625, APX725 and APX825
e. Locate and remove 1 in. NPT external gas
shutoff valve (required).
f. Models APX625, APX725 and APX825 have
1 in. NPT black nipple and left side panel
grommet factory installed.
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 24 “ Recommended Gas Piping”.
Table 19: Min./Max. Pressure Ratings
LP Gas
Natural Gas
Min. Pressure
Min. Pressure
Inlet to Gas
Inlet to Gas Valve
Valve
(in. w.c.)
(in. w.c.)
Boiler
Model
No.
Natural/LP
Gas Max.
Pressure
(in. w.c.)
APX425
13.5
4.0
13.5
4.5
APX525
APX625
APX725
11.0
APX825
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.
53
VII. Gas Piping (continued)
C. Pressure test. See Table 19 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.
DANGER
Explosion Hazard. Do not use matches, candles,
open flames or other ignition source to check for
leaks.
D. Apex Models APX525, APX625, APX725
and APX825 (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 Table 19.
The switches are preset for natural gas. For LP gas,
the low gas pressure switch setting must be adjusted.
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 19.
3. The gas pressure can be measured at the gas
valve inlet pressure port. Refer to Figure 25 “Gas
Inlet Pressure Tap and Pressure Switch Location “.
4. If either pressure switch is tripped, it must be
manually reset before the boiler can be restarted.
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 24.
3. An additional gas pressure regulator(s) may need
to be installed to properly regulate inlet gas pressure
at the smallest individual module (boiler).
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.
Figure 25: Gas Inlet Pressure Tap
and Pressure Switch Location
54
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
This boiler is equipped with a high water temperature limit located inside the internal wiring of the
boiler. This limit provides boiler shutdown in the event the boiler water temperature exceeds the set
point of the limit control. Certain local codes require an additional water temperature limit. In addition,
certain types of systems may operate at temperatures below the minimum set point of the limit
contained in the boiler.
If this occurs, install an additional water temperature limit (Honeywell L4006 Aquastat). Wire as
indicated in the Electrical Section of this manual.
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.
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. Connect the main power supply and
ground to the 3 boiler wires (black, white and green)
located in the junction box at top left side of the boiler
jacket.
C. Refer to Figures 26 and 27 for details on the
internal boiler wiring.
Line Voltage (120 VAC) Connections - see Figure 27.
1. The line voltage connections are located in the
junction box on the left side of the vestibule. The
terminal block TB-1 in conjunction with terminal
screw identification label is attached to the junction
box combination cover/inside high voltage bracket.
2. The conductor insulation colors are:
a. Black – L1 line voltage “Hot”
b. White – L2 line voltage “Neutral” for boiler and
circulators
c. Red – Line voltage “Hot” for “Heating”
circulator, “System” circulator and “DHW”
circulator
d. Green – Ground connection
Low Voltage (24 VAC) Connections - see Figure 27.
55
VIII. Electrical (continued)
3. The terminal block TB-2 in conjunction with
terminal screw identification label is attached to
the junction box front and located inside Sage2.1
Control compartment on the left side.
D. Power Requirements
Nominal boiler current draw is provided in Table
20. 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.
4. The connections are (listed identification
label top to bottom):
• 1 – “Heating Thermostat”
• 2 – “Heating Thermostat”
• 3 – “DHW Temperature Switch”
• 4 – “DHW Temperature Switch”
• 5 – “Outdoor Sensor”
• 6 – “Outdoor Sensor”
• 7 – “Header Sensor”
• 8 – “Header Sensor”
• 9 – “Remote Firing Rate -”
• 10 – “Remote Firing Rate +”
• 11 – “External Limit”
• 12 – “External Limit”
5.If the outdoor sensor is connected to
terminals 5 and 6 “Outdoor Sensor”, 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.
Table 20: Boiler Current Draw
56
Nominal Current
(amps)
APX425
<7
APX525
<6
APX625
<8
APX725
<8
APX825
<8
E. Flow Switch Wiring
Apex boilers include factory provided flow switch to
prevent boiler overheating. See Section VI, Water Piping
and Trim for pertinent details.
The flow switch is an operating control and must be used in
combination and wired in series with boiler safety high limit
control and other safety controls where applicable.
Wiring of the switch to boiler, including wire and conduit
supplies, is the responsibility of the installing contractor.
Use properly rated temperature wire for the anticipated
service temperature. Make all electrical connections in
accordance with the National Electrical Code, NFPA 70,
and/or Canadian Electrical Code Part 1, CSA C22.1 and
local codes, where applicable.
To wire the installed flow switch proceed as follows:
1. Remove jumper that is factory installed between
terminals 11 and 12 at the low voltage terminal strip
located inside boiler control panel assembly.
2. Using installer-provided wire and conduit,
wire the switch NO (normally open) terminal to
the terminal 11 and, the switch COM (common)
terminal to terminal 12. Also see/follow Taco
Instruction Sheet for Flow Switch Kit supplied
with the flow switch for specific details and Figure
26 “Ladder Diagram” and Figure 27 “Connection
Diagram” in this section.
NOTICE
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 (Sage2.1). One
example of an external power source that could
be inadvertently connected to the low voltage
connections is a transformer in old thermostat
wiring.
Model Number
F. Multiple Boiler Wiring
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.
VIII. Electrical (continued)
Figure 26: Ladder Diagram
57
58
VIII. Electrical (continued)
59
VIII. Electrical (continued)
Figure 27: Wiring Connections Diagram
VIII. Electrical (continued)
Figure 28A: 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
60
61
4
3
2
1
5
4
3
2
1
5
4
3
2
1
5
FLAIR "VJ"
ZONE VALVES
(SEE NOTE)
2
RD
YE
1 3
1 3
2
RD
YE
4
2
RD
YE
4
3
2
1
2
3
2
1
RD
YE
2
RD
YE
1 3
4
2
3
2
YE
WHITE ROGERS
#1361-102
ZONE VALVES
2 WIRE (24V) THERMOSTATS
W/ HEAT ANTICIPATOR SET
AT 0.3 AMPS (40VA REQ'D
FOR EVERY 4 ZONE VALVES)
HONEYWELL V8043E
ZONE VALVES
2 WIRE (24V) THERMOSTATS
W/ HEAT ANTICIPATOR SET
AT 0.5 AMPS (40VA REQ'D
FOR EVERY 4 ZONE VALVES)
TACO ZONE VALVES
(SEE NOTE)
2 WIRE (24V) THERMOSTATS
W/ HEAT ANTICIPATOR SET
AT 0.9 AMPS (40VA REQ'D
FOR EVERY 3 ZONE VALVES)
Figure 28B: 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
X4
X3
X2
X1
X4
X3
X2
X1
X4
X3
X2
X1
FIELD INSTALLED
40VA TRANSFORMER
(SEE NOTE)
2 WIRE (24V) THERMOSTATS
W/ HEAT ANTICIPATOR SET
AT 0.9 AMPS (40VA REQ'D
FOR EVERY 6 ZONE VALVES)
TO SAGE2
HEATING T-STAT
POWER L1
SUPPLY
120/60/1 N
NOTE:
CHECK FOR CROSS-PHASING BETWEEN BOILER TRANSFORMER AND FIELD SUPPLIED
TRANSFORMER ON TACO AND FLAIR ZONE VALVE CIRCUITS. IF CROSS-PHASING OCCURS,
CORRECT BY SWITCHING X1 AND X2 OR X3 AND X4. ALSO, BOILER SECONDARY SIDE (24V) IS
GROUNDED ON EI AND CANADIAN MODELS AND THE ZONE CIRCUIT MAY NOT OPERATE IF A
SEPARATE GROUND IS MADE IN THE ZONE CIRCUIT.
X4
X3
X2
X1
VIII. Electrical (continued)
62
VIII. Electrical (continued)
Figure 29: Multiple Boiler Wiring Diagram
Internal Sage2.1 Multiple Boiler Control Sequencer
(Three Boilers Shown, Typical Connections for up to Eight Boilers)
63
Tekmar 265 Based Control System (or equal)
Sequence of Operation
Figure 30A: 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 Sage2.1™ 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)
64
Tekmar 264 Based Control System (or equal)
Sequence of Operation
Figure 30B: 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 Sage2.1™ 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 de-energize 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)
G. External Multiple Boiler Control System
As an alternate to the Sage2.1 Control internal sequencer,
the Sage2.1 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 30A and 30B) are provided as examples
of typical multiple boiler control systems.
H. Multiple Boiler Operating Information
1. Required Equipment and Setup
a. Header Sensor (P/N 101935-01 or 103104-01)
A header sensor must be installed and wired
to the Master Sequencer “enabled” Sage2.1
Controller. The header sensor is installed on the
common system piping and provides blended
temperature information to the Sequence Master.
Refer to piping diagram Figure 23A on page 49
for installation location and Figure 31 or 32 for
installation detail.
b. RJ45 Splitters (P/N 103192-01)
RJ45 Splitters are required for installing
communications between three or more boilers.
When two boilers are connected the splitter is
not required.
c. 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 terminal J3, Modbus 2,
terminals A, B and V- between each boiler.
Refer to Figures 26 and 27 terminal J3 for wiring
location.
Figure 31: Recommended Direct Immersion
Header Sensor Installation Detail
Figure 32: Alternate “Immersion” type Header
Sensor Installation Detail
65
VIII. Electrical (continued)
G. Multiple Boiler Operating Information
(continued)
Figure 33: RJ45 Splitter Installation Detail
1. Required Equipment and Setup (continued)
d. Multiple Boiler Setup
Step
Description
1
Install and wire the Header
Sensor
2
Install Ethernet Cables
between boilers
3
Apply Power to All Boilers
4
Set Unique Boiler
Addresses
5
Enable 1 Boiler Master
6
8
Power Down All Boilers
Power Up Master
Sequencer
“Enabled” Boiler First
Power Up Other Boilers
9
Confirm Communication
7
Comments
Wire the header sensor to low voltage terminal strip terminals “Header sensor”.
NOTE
This step can not be skipped. The Sequence Master can not be “enabled” unless a Header
Sensor is installed.
Standard Ethernet type cables with RJ45 connectors are “plugged in” to the Boiler-to-Boiler
Communication Network connection located on the side of the boiler. When more than two
boilers are connected an RJ45 splitter may be used to connect the boilers. Refer to Figure
33.
Assign all boilers a unique Boiler Address using any number from 1 through 8.
WARNING
When two boiler’s addresses are the same undesirable simultaneous operation occurs.
Enable only one Sage2.1 Control’s Sequencer Master.
WARNING
When more than one Sequencer Master is enable erratic behavior will result.
From the Home Screen of the Sage2.1 Control with the Master Sequencer “enabled”, select
the Status button. The Sequencer display shows the boiler address of the communicating
boilers. Additionally, from the “Home” screen select the “Detail” button and then the
“Networked Boilers” buttons to view boiler communication status.
If a boiler is not shown, check Ethernet cable connections and confirm all boilers have unique
addresses.
66
IX. System Start-up
F. Prepare to check operation.
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.
A. Verify that the venting, water piping, gas
piping and electrical system are installed
properly. Refer to installation instructions contained
in this manual.
B. Confirm all electrical, water and gas
supplies are turned off at the source and that
vent is clear of obstructions.
C. Confirm that all manual shut-off gas valves
between the boiler and gas source are closed.
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 20 psi (140 kPa).
Purge air from the system.
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.
E. Confirm that the boiler and system have no
water leaks.
1. Obtain gas heating value (in Btu per cubic foot)
from gas supplier.
2. Apex gas valves have inlet and outlet
pressure taps with built-in shut off screw. Turn
each screw from fully closed position three to four
turns counterclockwise to open taps. Connect
manometers to pressure taps on gas valve.
NOTICE
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.
3. Temporarily turn off all other gas-fired
appliances.
4.Turn on gas supply to the boiler gas piping.
5.Open the field installed manual gas shut-off valve
located upstream of the gas valve on the boiler.
6. Confirm that the supply pressure to the gas valve
is 13.5 in wc (3.4 kPa) or less. Refer to Table 19 on
page 53 for minimum supply pressure.
7. Using soap solution, or similar non-combustible
solution, electronic leak detector or other approved
method, check that boiler gas piping valves, and
all other components are leak free. Eliminate any
leaks.
DANGER
Explosion Hazard. Do not use matches, candles,
open flames or other ignition source to check for
leaks.
8. Purge gas line of air.
G. Operating Instructions
Start the boiler using the Operating Instructions, see
Figure 34. After the boiler is powered up, it should go
through sequence of operation shown in Table 27 on
page 79.
H. Purge Air From Gas Train
Upon initial start-up, the gas train will be filled with air.
Even if the gas line has been completely purged of air,
67
IX. System Start-up (continued)
Apex Series Operating Instructions
Figure 34: Operating Instructions
68
IX. System Start-up (continued)
Status
Control Action
Initiate
Power-up
WARNING
This state is entered when a delay is
Standby Delay needed before allowing the burner control
to be available and for sensor errors.
Standby
Boiler is not firing. There is no call for
heat or there is a call for heat and the
temperature is greater than setpoint.
Safe Startup
Tests flame circuit then checks for flame
signal.
Drive Purge
Driving blower to purge rate setting and
waiting for the proper fan feedback.
Prepurge
Purges the combustion chamber for the
10 second purge time.
Drive Light-off
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.
Driving blower to light-off rate setting and
waiting for the proper fan feedback.
Pre-ignition
Test
Tests the safety relay and verifies that
downstream contacts are off.
Pre-ignition
Energizes the igniter and checks for
flame.
Direct
Ignition
Opens main fuel valve and attempts
to ignite the main fuel directly from the
ignition source.
Running
Normal boiler operation. Modulation rate
depends on temperature and setpoint
selections and modulating control action.
Postpurge
Purges the combustion chamber for the
30 second purge time.
Lockout
Prevents system from running due to a
detected problem and records fault in
Lockout History.
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.
I. Check Burner Flame
Inspect the flame visible through the window. On high
fire the flame should be stable and mostly blue (Figure
35). No yellow tipping should be present; however,
intermittent flecks of yellow and orange in the flame are
normal.
J. 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.
K. Models APX425 and APX525 only: For LP
Gas, perform procedure as described in Paragraph R
“Field Conversion From Natural Gas to LP Gas” before
starting Paragraph L “Checking/Adjusting Gas Input
Rate”.
For natural gas, proceed to Paragraph L “Perform
Combustion Test”.
L. 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.
1. Remove flue temperature sensor from vent
connector (see Figure 9 on page 22) and insert
combustion analyzer probe through flue temperature
sensor silicon cap opening. If required, also remove
the flue temperature sensor silicon cap and insert
the analyzer probe directly into flue sensor port.
Reinstall the sensor and the cap upon combustion
testing completion.
2. Verify O2 (or CO2) and CO are within limits specified in Table 21 (natural gas) or Table 22 (LP
gas) at both high and low fire as described in the
following steps.
Table 21: Typical Combustion Settings,
Natural Gas
Boiler
Model
High Fire
% CO2
% O2
Low Fire
% CO2
% O2
APX425
9.9 - 8.2 3.5 - 6.5 9.3 - 7.9 4.5 - 7.0
APX525
9.3 - 7.9 4.5 - 7.0 9.3 - 7.9 4.5 - 7.0
APX625
9.1 - 8.5 4.9 - 6.0 9.1 - 7.5 4.9 - 7.7
APX725
8.7 - 8.3 5.6 - 6.3 8.7 - 7.5 5.6 - 7.7
APX825
9.3 - 7.9 4.5 - 7.0 9.3 - 7.9 4.5 - 7.0
CO,
PPM
Less than
100 PPM
69
IX. System Start-up (continued)
Figure 35: Burner Flame
Table 22: Typical Combustion Settings,
LP Gas
High Fire
Boiler
Model
% CO2
Low Fire
% O2
% CO2
% O2
3.5 - 7.0
APX425 11.4 - 9.5
3.5 - 6.5
11.4 - 9.1
APX525 10.8 - 9.1
4.5 - 7.0
10.8 - 9.1 4.5 - 7.0
APX625
9.6 - 9.2
6.3 - 7.0
9.6 - 8.0
6.5 - 8.8
APX725
9.6 - 9.2
6.3 - 7.0
9.6 - 8.0
6.5 - 8.8
APX825 10.8 - 9.1
4.5 - 7.0
10.8 - 9.1 4.5 - 7.0
CO,
PPM
Less than
100 PPM
a. Lock boiler in high fire and allow boiler to
operate for approximately 5 minutes before
taking combustion readings. To lock boiler in
high fire, from the home screen, press “Adjust”,
“Adjust”, “Login”, “000”. Enter the password
“086” and press return arrow to close the keypad.
Press “Save”, “Adjust”, “High” to lock boiler in
high fire.
WARNING
The offset screw has been factory set using
precision instruments and must never be
adjusted in the field unnecessarily. The gas
valve outlet pressure is the same for both natural
gas and propane. Make sure that all adjustments
are made with the throttle, not the offset screw
(see Figure 36). Attempting to adjust the offset
screw unnecessary will result in damage to the
gas valve and may cause property damage,
personal injury or loss of life.
b. If high fire O2 is too low (CO2 is too high),
increase O2 (decrease CO2) by turning the throttle
screw 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 36 for location of throttle screw. Verify
CO is less than 100 ppm.
c. If high fire O2 is too high (CO2 is too low),
decrease O2 (increase CO2) by turning the
70
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 36 for location of throttle screw.
Verify CO is less than 100 ppm.
d. Lock boiler in low fire and allow boiler to
operate for approximately 5 minutes before
taking combustion readings. Press “Low” to
lock boiler in low fire.
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 21 or 22.
e. If low fire O2 is too low (CO2 is too high),
increase O2 (decrease CO2) by turning offset
screw counterclockwise in less than 1/8 turn
increments and checking the O2 (or CO2) after
each adjustment. If boiler is equipped with 2 gas
valves, offset screw adjustments must be done
to both gas valves equally and simultaneously.
Refer to Figure 36 for location of offset screw.
Verify CO is less than 100 ppm.
f. If low fire O2 is too high (CO2 is too low),
decrease O2 (increase CO2) by turning offset
screw clockwise in less than 1/8 turn increments
and checking the O2 (or CO2) after each
adjustment. If boiler is equipped with 2 gas
valves, offset screw adjustments must be done
to both gas valves equally and simultaneously.
Figure 36: Gas Valve Detail
IX. System Start-up (continued)
10. Return boiler to normal operating mode by
Refer to Figure 36 for location of offset screw.
Verify CO is less than 100 ppm.
pressing “Auto”.
3. Reinstall flue temperature sensor with silicone
11.Return other gas-fired appliances to previous
cap into two-pipe vent adapter.
4. Return boiler to normal operating mode by
pressing “Auto”.
condition of use.
N. Test Safety Limits Controls
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 27. The boiler must shut
down and must not start with the flame sensor
disconnected.
M.Checking / Adjusting Gas Input Rate
1.Turn off gas supply to all appliances other than
gas-fired boiler.
2. Lock the boiler in high fire, following Step 3a
in Paragraph L.
2. Test the flow switch by disabling the primary
3. Clock gas meter for at least 2 revolutions of
loop circulator. The boiler must not start if flow is
not present.
the dial, typically labeled ½ or 1 cubic foot per
revolution on the gas meter.
3. Test any other external limits or other controls
4. Determine gas flow rate in cubic feet per hour
based on elapsed time for 2 revolutions.
Example:
Using a meter with dial labeled 1 cubic foot per
revolution, measured time is 72 seconds for 2
Revolutions, i.e. 36 seconds per 1 cubic foot.
Calculate hourly gas flow rate:
3600 sec/hr ÷ 36 sec/cu ft = 100 cu ft/hr
5. Obtain gas-heating value (BTU per cubic foot)
from gas supplier.
in accordance with the manufacturer’s instructions.
O. 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.
P. 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 91)
of this manual for information on how to adjust supply
setpoint.
6.Multiply hourly gas flow rate by gas heating value
to determine the boiler input rate, BTU/hr
Example:
Natural gas heating value provided by local gas
utility is 1050 BTU per cubic foot.
Measured and calculated hourly gas flow rate is 100
cu ft/hr.
Measured boiler input rate is:
100 cu ft/hr * 1050 BTU/ cu ft = 105, 000 BTU/hr
7. Verify measured input rate is within 88% to
100% of the max. input listed on the boiler rating
label.
8. If measured input is too high, reduce maximum
modulation fan speed (either central heat or
domestic hot water, depending on source of call for
heat) in increments of 50 RPM and check the input
rate after each adjustment. Follow instructions in
Section X. “Operation” to adjust the maximum
modulation fan speed.
9. If measured input is too low, increase maximum
modulation fan speed (either central heat or
domestic hot water, depending on source of call for
heat) in increments of 50 RPM and check the input
rate after each adjustment. Follow instructions
in Section X “Operation” to adjust the maximum
modulation fan speed.
Q. Adjust Thermostats
Adjust the heating and indirect water heater thermostats
to their final set points.
R. Field Conversion From Natural Gas to LP
Gas
Apex models APX425 and APX525 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 APX625, APX725 and APX825 are factory
shipped as either natural gas build or LP gas build.
Field conversions of models APX625, APX725 and
APX825 are not permitted.
1.Conversion of Apex models APX425 and APX525
from one fuel to another is accomplished using
the throttle screw on the gas valve. Figure 36 “Gas
Valve Detail” shows the location of the throttle
screw on the valve. Locate the throttle screw on the
boiler being converted.
71
IX. System Start-up (continued)
WARNING
WARNING
Asphyxiation Hazard. The throttle adjustments
shown in Table 23 are approximate. The
final throttle setting must be found using a
combustion analyzer. Leaving the boiler in
operation with a CO level in excess of the value
shown in Table 22 could result in injury or death
from carbon monoxide poisoning.
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.
5. After the burner lights, complete all steps outlined
in Paragraph L “Perform Combustion Test” and
Paragraph M “Checking/Adjusting Gas Input Rate”
before proceeding.
6. Verify that the gas inlet pressure is between the upper
and lower limits shown in Table 19 on page 53 with
all gas appliances (including the converted boiler)
both on and off.
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.
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) 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.
3.Before attempting to start the boiler, make the
number of turns to the throttle screw called for in
Table 23.
Table 23: Approximate Number of Clockwise
Throttle Screw Turns for LP Conversion
Boiler
Model
APX425
APX525
APX625
APX725
APX825
Gas Valve
GB-057 HO
(¾” NPT)
GB-057 HO
(¾” NPT)
GB-ND057 D01 S00 XP
(¾” NPT)
7. A label sheet is provided with the boiler for
1¾
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.
1
b. Apply the “Gas Valve Label” to a conspicuous area
on the gas valve.
Approximate Throttle
Screw Turns
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.
Factory LP Builds
4.Attempt to start the boiler using the Operating
Instructions located inside the lower front cover of
the boiler. If the boiler does not light on the first
try for ignition, allow to boiler to make at least
four more attempts to light. If boiler still does not
light, turn the throttle 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.
72
S. Correcting Throttle Screw Mis-Adjustment
(if required)
Alpine 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.
IX. System Start-up (continued)
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 24A for natural gas or Table 24B for LP
gas.
3. Follow instructions in Section L “Perform
Combustion Test” to verify O2 (or CO2) is within the
range specified in Table 21 for natural gas or Table
22 for LP gas at both high fire and low fire.
WARNING
The throttle adjustment values shown in Table
24A and Table 24B are approximate. The
final throttle setting must be found using a
combustion analyzer.
Table 24A: Approximate Throttle Screw
Adjustment Values from Fully Closed
Position, Natural Gas
Boiler
Throttle Position (Number of CounterModel clockwise Turns from Fully Closed Position
APX425
4 & 3/4
APX525
4 & 3/4
APX625
6
APX725
10
APX825
7 & 1/2
Table 24B: Approximate Throttle Screw
Adjustment Values from Fully Closed
Position, LP Gas
Boiler
Model
Throttle Position (Number of Counterclockwise Turns from Fully Closed Position
APX425
3
APX525
3 & 3/4
APX625
6
APX725
10
APX825
7 & 1/2
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 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
S “Correcting Throttle Screws Mis-Adjustment. Then, use a combustion analyzer to verify and adjust O2 (or
CO2) and CO to values shown in Table 21 for natural gas or Table 22 for LP gas.
73
IX. System Start-up (continued)
T. Controls Startup Check List
The Control is factory programmed with default parameters. Before operating the boiler, these parameters must be checked
and adjusted as necessary to conform to the site requirements. Follow the steps below, making selections and adjustments as
necessary to ensure optimal boiler operation.
No.
1
Title
Check
Wiring
Terminal
Description
1&2
Is the heating thermostat connected? Insure this is “dry”, non-powered input.
2&3
Is an Indirect Water Heater (IWH) providing a boiler heat demand?
5&6
Is an Outdoor Air sensor used? If no, select outdoor sensor type “not installed” under
system menu.
7&8
Is a header sensor used? If yes, refer to step 10 below to activate this feature.
9 & 10
Is a Remote 4-20mA required for a Energy Management System or external multiple
boiler control? If used see step 9 below to activate this input.
11 & 12
Is a Flow Switch (where applicable) and/or External Limit used? Remember to remove
factory-installed jumper.
LWCO Plug
Is a LWCO required? Check installation of the LWCO.
From the Home Screen press the Adjust button and login to access the adjust mode screens (if required, refer to X. Operation
Section, “Entering Adjustment Mode” Paragraph G, 1 for login instructions). The following parameters should be reviewed:
No.
Menu
2
System
Setup
3
Modulation
Setup
4
Pump
Setup
5
Contractor
Setup
Parameter
Description
Warm Weather
Shutdown
Selecting “Enable” will restrict boiler start during warm weather (only if an outdoor air
temperature sensor is installed).
Warm Weather
Shutdown Setpoint
Use this setting to adjust the temperature that the WWSD function will shut boiler off.
Boiler Type
WARNING
Confirm that the correct boiler model is shown. Stop installation and contact factory if
the wrong boiler model is shown.
System Pump
Boiler Pump
Domestic Pump
Contractor Name
Address
Phone
Enter your contact information, name, address, and phone number on this screen.
In the event of a fault or the need to adjust a setting the display will direct the
homeowner to you.
6
Manual
Control
7
Central
Heat
8
DHW
9
Remote
4-20mA
Modulation Source
Setpoint Source
Set to 4-20mA when a Energy Management system is sending a “remote” setpoint.
10
Sequencer
Master Slave
Refer to Sequencer Master Setup Section X, G if multiple boilers are installed at this
site.
74
Manual Speed
Control
Ensure that the pump parameter selections are correct for your heating system. Refer
to Paragraph G. Adjusting Parameters, Pump Setup Menu for additional information.
Use the “High and “Low” options to force the boiler to high fire and low fire for
combustion testing.
Setpoint
Ensure Setpoint, (firing rate target temperature) is correct for your type of radiation.
Setback
Setpoint
Check the setting for the central heat setpoint when the T-Stat “Sleep” or “Away”
Setback mode is entered (if EnviraCOM Setback thermostat is used).
Setpoint
Ensure Setpoint, (firing rate target temperature) is suitable for the IWH requirements.
Setback
Setpoint
Check the setting for the DHW setpoint when the T-Stat “Sleep” or “Away” Setback
mode is entered (if EnviraCOM Setback thermostat is used).
Set to 4-20mA when an external multiple boiler controller is connected to the system.
X. Operation
A. Overview
1. Sage 2.1 Controller
The Sage 2.1 Controller (Control) contains features and
capabilities which help improve heating system operation,
and efficiency. By including unique capabilities, the Control
can do more, with less field wiring, and fewer aftermarket
controls and components – improving the operation of both
new and replacement boiler installations.
2. Advanced Touch Screen Display
i
Status
Detail
Help
Boiler 1
180 F
Standby
Energy Save On
Adjust Max Efficiency On
Home Screen
Boiler status and setup selections are available from an
easy to use, dual color, LCD Touch Screen Display. Over
one hundred helpful information screens are provide to
explain status information and setup functions. 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.
3. Advanced Modulating Control
The Control modulates the boiler input by varying the fan
speed. As the fan speed increases, so does the amount of
fuel gas drawn into the blower. As a result, a fairly constant
air-fuel ratio is maintained across all inputs. The Control
determines the input needed by looking at both current and
recent differences between the measured temperature and
the setpoint temperature. As the measured temperature
approaches the setpoint temperature, the fan will slow down
and the input will drop. The Control also utilizes boiler
return water and flue gas temperatures to adjust fan speed.
4. Built-in Safety Control
The Control includes safety controls designed to ensure safe
and reliable operation. In addition to flame safety controls
the Control includes supply water temperature, differential
water temperature, and stack temperature safety limits and
stepped modulation responses. Boiler modulation is adjusted
when required to help avoid loss of boiler operation due
to exceeding limits. Additionally, the Control accepts the
field installation of flow switch and optional auxiliary safety
limits.
5. Outdoor Air Reset
When selected the modulation rate setpoint is automatically
adjusted based on outside air temperature, time of day and
length of demand (boost) settings. Outdoor air “reset”
setpoint saves fuel by adjusting the water temperature of
a heating boiler lower as the outside air temperature
increases.
6. Warm Weather Shutdown (WWSD)
Some boilers are used primarily for heating buildings,
and the boilers can be automatically shutdown when
the outdoor air temperature is warm. When outside air
temperature is above the WWSD setpoint, this function
will shut down the boiler, boiler pump and/or the system
pump.
7. Domestic Hot Water Priority (DHWP)
Some boilers are used primarily for building space heating,
but also provide heat for the domestic hot water users.
When the outdoor temperature is warm, the outdoor reset
setpoint may drop lower than a desirable domestic hot
water temperature. Also, often it is required to quickly
recover the indirect water heater. When DHWP is
enabled, heating circulators are stopped, the domestic
circulator is started and the domestic hot water setpoint is
established in response to a domestic hot water demand.
Priority protection is provided to allow the heating loop
to be serviced again in the event of an excessively long
domestic hot water call for heat.
8. Energy Management System (EMS) Interface
The control accepts a 4-20mAdc input from the EMS
system for either direct modulation rate or setpoint.
9. Circulator Control
The Control may be used to sequence the domestic hot
water, boiler and system circulators. Service rated relay
outputs are wired to a line voltage terminal block for easy
field connection. Simple parameter selections allow all
three pumps to respond properly to various hydronic
piping arrangements including either a boiler or primary
piped indirect water heater. Circulators are automatically
run for a 20 second exercise period after not being used
for longer than 7 days. Circulator exercise helps prevent
pump rotor seizing.
10. Multiple Boiler Sequencer Peer-To-Peer
Network
The Control includes state-of-the-art modulating lead-
lag sequencer for up to eight (8) boilers capable of auto
rotation, outdoor reset and peer-to-peer communication.
The peer-peer network is truly “plug and play”.
Communication is activated by simply connecting a RJ45
ethernet cable between boilers. The Control provides
precise boiler coordination by sequencing boilers based
on both header water temperature and boiler modulation
rate. For example, the lead boiler 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.
75
X. Operation B. Supply Water Temperature Regulation (continued)
11. Modbus Communication Interface
A factory configured RS485 Modbus interface is available
for Energy Management System (EMS)monitoring when
not used for Multiple Boiler Sequencer Peer-To-Peer
Network. Consult factory if this interface must be used
in addition to the boiler Peer-to-Peer Network.
B. Supply Water Temperature Regulation
1. Priority Demand
The Control accepts a call for heat (demand) from
multiple places and responds according to it’s “Priority”.
When more than 1 demand is present the higher priority
demand is used to determine active boiler settings.
For example, when Domestic Hot Water (DHW) has
priority the setpoint, “Diff Above”, “Diff Below” and
pump settings are taken from DHW selections. Active
“Priority” is displayed on the “Boiler Status” screen.
Table 25: Order of Priority
Priority
1st
2nd
3rd
4th
5th
6th
Status
Screen
Display
Sequencer
Control
Boiler Responding to:
The boiler is connected to the peerto-peer network. The boiler accepts
demand from the Sequencer Master.
Domestic Hot DHW call for heat is on and selected
Water
as the priority demand. DHW is
always higher priority than Central
Heat. It also has higher priority than
the Sequencer Control when DHW
priority is “enabled” and “Boiler Piped”
IWH is selected.
Central Heat Central Heat call for heat is on and
there is no DHW demand or DHW
priority time has expired.
Frost
Frost Protection is active and there is
Protection
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.
Warm
WWSD is active and the boiler will
not respond to central heat demands.
Weather
Shutdown
DHW demand is not blocked by
WWSD.
(WWSD)
Standby
There is no demand detected.
2. Setpoint Purpose
The Control starts and stops the boiler and modulates
the boiler input from minimum (MBH) to maximum
(MBH) in order to heat water up to the active setpoint.
The setpoint is determined by the priority (Central Heat
or Domestic Hot Water) and as described in the following
paragraphs.
3. Central Heat Setpoint
Upon a Central Heat call for heat the setpoint is either
76
the user entered Central Heat Setpoint or is automatically
adjusted by a thermostat’s “Sleep” or “Away” modes and/
or Outdoor Air Reset or a Energy Management System
(EMS) supplied 4-20mAdc setpoint.
4. Outdoor Air Reset
If an outdoor temperature sensor is connected to the boiler
and Outdoor Reset is enabled, the Central Heat setpoint
will automatically adjust downwards as the outdoor
temperature increases. When the water temperature is
properly matched to heating needs there is minimal chance
of room air temperature overshoot. Excessive heat is
not sent to the room heating elements by “overheated”
(supply water temperature maintained too high a setting)
water. Reset control saves energy by reducing room
over heating, reducing boiler temperature & increasing
combustion efficiency and reducing standby losses as a
boiler and system piping cool down to ambient following
room over heating.
5. Boost Time
When the Central Heat Setpoint is decreased by Outdoor
Air 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 feature increases the operating
temperature setpoint by 10°F (5.6°C) every 20 minutes
(field adjustable) the central heat demand is not satisfied.
This process will continue until heat demand is satisfied
(indoor air is at desired temperature). Once the heat
demand is satisfied, the operating setpoint reverts to the
value determined by the Outdoor Air Reset settings. If
Boost Time is zero, then the boost function is not used.
6. Domestic Hot Water (DHW) Setpoint
Upon a DHW call for heat the setpoint is either the user
entered DHW setpoint or the Thermostat’s “Sleep” or
“Away” DHW setpoint. The optimal value of this setpoint
is established based on the requirements of the indirect
water heater.
7. Domestic Hot Water Priority (DHWP)
When domestic hot water priority is selected and there
is a DHW call for heat, the system pump will be turned
off (when system pump run pump for parameter is set for
“Central Heat Optional Priority”) and the DHW pump will
be turned on. Additionally, if outdoor reset is active, the
active setpoint is adjusted to the DHW Setpoint. Priority
protection is provided to ensure central heat supply in
the case of excessively long DHW call for heat.
8. “Setback” Setpoints
User adjustable Thermostat “Sleep” or “Away” Setback
Setpoints are provided for both Central Heat and
DHW demands. The Setback setpoint is used when the
EnviraCOM thermostat is in “leave” or “sleep” modes.
When setback is “on” the thermostat setback setpoint
shifts the reset curve to save energy while the home is
in reduced room temperature mode. The Honeywell
VisionPro IAQ (part number TH9421C1004) is a
“setback” EnviraCOM enabled thermostat.
X. Operation C. Boiler Protection Features (continued)
C. Boiler Protection Features
1. Supply Water Temperature High Limit
The boiler is equipped with independent automatic reset and a
manual reset high limit devices. A supply manifold mounted
limit device provides the automatic reset high limit. The
automatic high limit is set to 200°F (93.3°C). The control
monitors a supply water temperature sensor that is also
mounted in the supply water manifold and an internal, manual
reset high limit. If supply water temperature exceeds 190°F
(87.7°C), the control begins to reduce the blower maximum
speed setting. If the temperature exceeds 200°F (93.3°C),
a forced recycle results. If the temperature exceeds 210°F
(98.9°C), a manual reset hard lockout results. Additionally, if
the supply temperature rises faster than the degrees Fahrenheit
per second limit a soft lockout is activated.
2. High Differential Temperature Limit
The Control monitors the temperature difference between the
return and supply sensors. If this difference exceeds 43°F
(23.9°C) the control begins to reduce the maximum blower
speed. If temperature difference exceeds 53°F (29.4°C) a
forced boiler recycle results. If the temperature difference
exceeds 63°F (35°C) the control will shut the unit down. The
unit will restart automatically once the temperature difference
has decreased and the minimum off time has expired.
3. Flow Switch
For coil-type water boilers requiring forced circulation with
5. External Limit
An external limit control can be installed between
terminals 11 and 12 on the low voltage terminal strip. Be
sure to remove the jumper when adding an external limit
control to the system. If the flow switch is installed, any
additional external limit must be wired in series with the
flow switch. If the external limit opens, the boiler will
shut down and an open limit indication and error code
is provided. If the limit installed is a manual reset type,
it will need to be reset before the boiler will operate.
6. Boiler Mounted Limit Devices
The Control monitors individual limit devices: pressure
switch, high limit device, condensate level switch,
Thermal Link, Burner Door Thermostat with manual
reset, flow switch, fuel gas pressure switches (optional)
and external limit (optional). If any of these limits opens,
the boiler will shut down and an individual open limit
indication is provided.
7. Stack High Limit
The Control monitors the flue gas temperature sensor
located in the vent connector. If the flue temperature
exceeds 184°F (84.4°C), the control begins to reduce the
maximum blower speed. If the flue temperature exceeds
194°F (90.0°C), a forced boiler recycle results. If the
flue temperature exceeds 204°F (95.6°C), the control
activates a manual reset Hard Lockout.
8. Ignition Failure
input rating greater than or equal to 400,000 BTU/hr, ASME
The Control monitors ignition using a burner mounted
Boiler and Pressure Vessel Code requires a flow switch in
flame sensor. In the event of an ignition failure:
lieu of low water cutoff. ALSO ADHERE TO ALL LOCAL
CODE REQUIREMENTS. Contact your local code inspector
• Model APX425 - the control retries 5 times and
prior to installation.
then goes into soft lockout for one hour.
The flow switch is an operating control, which must be used
• Models APX525, APX625, APX725 and APX825 - the
in conjunction with supply water temperature high limit. It
control retries 1 time and then goes into hard lockout.
is factory provided with Apex boilers and must be installed
Manual reset is required to resume boiler operation.
as part of near boiler piping (see Section VI ‘Water Piping
9. Central Heating System Frost Protection
and Trim’ of these instructions).
When enabled, Frost Protection starts the boiler and
The control shuts down the boiler when the water flow in
system pump and fires the boiler when low outside air
boiler primary loop is either non-existent or too low. This
and low supply water temperatures are sensed. The
ensures the boiler shutdown to prevent boiler overheating.
Control provides the following control action when frost
When water flow is restored to a boiler-specific minimum
protection is enabled:
flow value (see Table 12 ‘Flow Range requirement Through
Boiler’) the switch will detect the flow and restart boiler Table 26: Frost Protection
automatically.
Device
Start
Stop
If the flow switch opens, the boiler will shut down and an
Started
Temperatures
Temperatures
open limit indication and error code is provided.
Boiler & System
Outside Air < 0°F (-18°C)
Outside Air > 4°F (-15°C)
4. Return Temperature Higher Than Supply
Temperature (Inversion Limit)
The Control monitors the supply and return temperature
sensors. If the return water temperature exceeds the 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 manual reset Hard Lockout is set. This condition is the
result of incorrectly attaching the supply and return piping.
Pump
Supply Water < 45°F (7.2°C) Supply Water > 50°F (10°C)
Boiler
Supply Water < 38°F (3.3°C) Supply Water > 50°F (10°C)
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.
77
X. Operation D. Multiple Boiler Control Sequencer (continued)
D. Multiple Boiler Control Sequencer
1. “Plug & Play” Multiple Boiler Control Sequencer
When multiple boilers are installed, the Control’s
Sequencer may be used to coordinate and optimize the
operation of up to eight (8) boilers. Boilers are connected
into a “network” by simply “plugging in” standard
ethernet cables into each boiler’s “Boiler-To-Boiler
Communication” RJ45 connection.
2. Sequencer Master
A single Control is parameter selected to be the Sequencer
Master. The call for heat, outdoor and header sensors,
and common pumps are wired to the Sequencer Master
“enabled” Control.
3. Lead/Slave Sequencing & Equalized Run Time
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.
4. Improved Availability
The following features help improve the heat availability:
a. Backup Header Sensor: In the event of a header sensor
failure the lead boiler’s supply sensor is used by the
Sequence Master to control firing rate. This feature
allows continued coordinated sequencer control even
after a header sensor failure.
b. “Stand Alone” Operation Upon Sequence Master
Failure: If the Sequence Master Control is powered
down or disabled or if communication is lost
between boilers, individual boilers may be setup to
automatically resume control as a “stand alone” boiler.
c. Slave Boiler Rate Adjustment: Each slave boiler
continues to monitor supply, return and flue gas
temperatures and modifies the Sequence Master’s
firing rate demand to help avoid individual boiler
faults, minimize boiler cycling and provide heat to
the building efficiently.
d. Slave Boiler Status Monitoring: The Sequence Master
monitors slave boiler lockout status and automatically
skip over disabled boilers when starting a new slave
boiler.
5. 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.
78
6. Multiple Demands
The Sequence Master responds to Central Heat, DHW
and frost protection demands similar to the stand alone
boiler. For example, when selected and DHW priority
is active, the sequence master uses DHW setpoint, “Diff
Above”, “Diff Below” and pump settings.
7. Shared or Isolated DHW Demand
When the Indirect Water Heater (IWH) parameter is set
to “Primary Piped” the Sequence Master sequences all
required boilers to satisfy the DHW setpoint (default
180°F (82.2°C). When “Boiler Piped” is selected only
the individual slave boiler, with the wired DHW demand
and pump, fires to satisfy the DHW setpoint.
8. DHW Two boiler Start
When the Indirect Water Heater (IWH) parameter is set to
“Primary Piped” and the DHW Two Boiler Start parameter
is set to “Enabled” two boilers are started without delay
in response to a DHW call for heat. This feature allows
rapid recovery of large IWH’s and multiple IWH’s.
9. 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 Sequence Master develops
a unison firing rate demand based on it’s setpoint and
sensed header temperature.
10. Innovative Condensing Boiler Control
During low loads, the Sequence Master limits firing rates
to a ‘Base Load Common Rate” to ensure 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 Common Rate” until
the last lag boiler is started. At this point, the “Base Load
Common Rate” is released to allow boilers to modulated
as required to meet heat load.
11. Advanced Boiler Sequencing
After there is a Call For Heat input, both header water
temperature and boiler firing rate percent are used to start
and stop the networked boilers. The control starts and
stops boilers when the water temperature is outside the
user selected “Diff Above” and “Diff Below” settings.
Also, in order 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.
12. Stop All Boilers
All boilers are stopped without delay if the Call for Heat
input is removed or if the header temperature is higher
than 195°F (90.6°C) (field adjustable).
X. Operation E. Boiler Sequence Of Operation (continued)
E. Boiler Sequence of Operation
1. Normal Operation
Table 27: Boiler Sequence of Operation
Status Screen Display
i
<
i
<
i
<
i
<
i
<
i
<
Boiler 1
140 F
140 F
Rate
0%
Supply
Setpoint
>
Priority: Standby
Status: Standby
Boiler 1
140 F
140 F
Rate
0%
Supply
Setpoint
>
Priority: Central Heat
Status: Standby
Boiler 1
132 F
140 F
Rate 98%
Supply
Setpoint
Priority: Central Heat
Status: Prepurge
Boiler 1
132 F
140 F
Rate 89%
Supply
Setpoint
>
10
>
Priority: Central Heat
Status: Direct Ignition
Boiler 1
132 F
140 F
Rate 100%
Supply
Setpoint
>
Priority: Central Heat
Status: Running
Boiler 1
132 F
180 F
Rate 100%
Supply
Setpoint
>
Priority: Domestic Hot Water
Status: Running
Priority:
Standby
Status:
Standby
Description
(burner Off, circulator(s) Off)
Boiler is not firing and there is no call for heat, priority equals standby. The boiler
is ready to respond to a call for heat.
Priority:
(burner Off, circulator(s) On)
Central Heat Boiler is not firing. There is a Central Heat call for heat and the Supply temperature
Status:
is greater than setpoint minus the “Diff Below”.
Standby
When supply temperature drops burner demand continues with following Status
Priority:
shown:
Central Heat Safe Startup:
Flame circuit is tested.
Drive purge:
The blower is driven to the fan purge speed.
Status:
Prepurge:
After the blower reaches the fan purge speed setting the 10
Prepurge
second combustion chamber purge is conducted.
After purge time is complete the following Status is shown:
Priority:
Central Heat Drive light-off: The blower is driven to light-off rate.
Pre-Ignition Test: After the blower reaches light-off rate a safety relay test is
Status:
conducted.
Direct
Pre-ignition:
Spark is energized and it is confirmed that no flame is present
ignition
Direct Ignition: Spark and Main fuel valve are energized.
Priority:
(burner On, circulator(s) On)
Central Heat
After flame is proven normal boiler operation begins. Modulation rate depending
Status:
on temperature and setpoint selections and modulating control action.
Running
Priority:
Domestic
Hot Water
Status:
Running
Priority:
Standby
Status:
Post-purge
Priority:
Standby
Status:
Standby
Delay
Priority:
Standby
Status:
Lockout
If the Central Heat call for heat is active and a Domestic Hot Water (DHW) call for
heat received the DHW demand becomes the “priority” and the modulation rate,
setpoint, “Diff Above” and “Diff Below” are based on DHW settings.
(burner Off, circulator(s) Off)
If there is no call for heat the main fuel valve is closed and the blower is driven
to the fan post-purge speed. After the blower reaches the fan post-purge speed
setting the 30 second combustion chamber purge is conducted.
This state is entered when a delay is needed before allowing the burner control to
be available. For example, when Anti-Short Cycle time is selected Standby delay
is entered after the Central Heat call for heat ends. Select “Help” button from the
“Home Screen” to determine the cause of the Standby Delay.
A lockout Status is entered to prevent the boiler from running due to a detected
problem. Select “Help” button from the “Home Screen” to determine the cause of
the Lockout. The last 10 Lockouts are recorded in the Lockout History.
79
X. Operation E. Boiler Sequence Of Operation (continued)
2. Using The Display
The Control includes a touch screen LCD display. The user monitors and adjusts boiler operation by selecting screen
navigation “buttons” and symbols. Navigation features are shown below.
The “Home Screen” and menu selections are shown below. When no selection is made, while viewing any screen, the
display reverts to the “Home Screen” after 4 minutes. The “Home Screen” displays boiler temperature, boiler status and
Efficiency Information. “Energy Save On” indication appears when the outdoor reset or setback features have lowered the
Central Heat Setpoint based on outside air temperature measurement or time of day. “Max Efficiency On” appears when
the boiler return temperature has been reduced low enough to cause energy saving flue gas condensation.
Menu Button
i
180 F
Detail
Help
The Home Screen Menu Buttons connect the displays four main display
groups; Status, Detail, Help and Adjustment Screens.
Boiler 1
Status
Standby
Energy Save On
Adjust Max Efficiency On
Home Screen
Close Symbol
The “Close” symbol returns to the display to previous menu or screen.
Repeatedly pressing the “Close” symbol will always return the display to the
“Home” screen.
i
<
Boiler 1 Active
180 F Fault
180 F
Rate
0%
Supply
Setpoint
Arrow Symbol
>
The “Arrow” symbol links together all screens in the selected group. For
example, repeated pressing the right “Arrow” symbol will rotate the display
around all the screens in the Status group. Using this feature the user can
review all the boiler status and adjustment mode screens.
Priority: Central Heat
Status: Standby
Status Screen
Fault Symbols
“Active Fault” and “Rate Limit” symbols provide a link to the cause of a boiler
fault or firing rate limit. The first boiler status screen provides an overview of
boiler operation including fault status.
Information Symbol
“Information” symbol links most screens to screen content explanations. New
terminology used in status and adjustment screens are explained in plain words.
Home Screen
i
Boiler 1
Status
180 F
Detail
Help
Standby
Energy Save On
Adjust Max Efficiency On
i
<
Boiler 1
Supply
Setpoint
180 F
180 F
0%
Rate
Priority:
Central Heat
Status: Standby
Status Screens
(see Figure 38)
80
i
Central Heat
>
Domestic
Hot Water
Outdoor
Reset Curve
Detail Menu
(see Figure 39)
Active Faults
Lockout
History
Sequencer
Setup
Service
Contract
Boiler Size
Setup
Help Menu
(see Figure 44)
Warning! Only Qualified Technicians
Should Adjust Controls, Contact Your
Qualified Heating Professional
Improper settings or service create risk of
property damage, injury, or death.
Service Contact
Adjust
Adjust Mode Screens
(see Figure 40)
X. Operation F. Viewing Boiler Status (continued)
F. Viewing Boiler Status
1. Status Screens
Boiler Status screens are the primary boiler monitoring screens. The user may simply “walk” though boiler
operation by repeatedly selecting the right or left “arrow” symbol. These screens are accessed by selected the
“Status” button from the “Home” screen.
i
<
i
Boiler 1
Supply
Setpoint
180 F
180 F
0%
Rate
Priority:
Central Heat
<
>
180 F
160 F
Stack 147 F
Rate 40 %
Supply
<
i
Heat Demand
Central Heat On
Domestic Hot Water Off
Sequence Master Off
Frost Protection Off
>
>
Return
Status: Standby
i
Trends
Status
i
Pump Status/Cycles
System On
Boiler On
DHW Off
<
Frost Protection On
98
23
0
<
>
<
Flame
2.5 hour trend
Supply / Return
Flame
5 minute trend
Firing Rate
>
Boiler Cycles/Hours
Boiler Cycles
2000
Run Time Hours
800
>
Exercise On
Figure 37: Status Screens
Active fault:
A hard lockout will cause the active
fault indication to appear. When
visible the text becomes a screen link
to the “Help” Menu.
Supply:
measured supply water temperature. This is the
temperature being used to start/stop and fire boiler
when there is a call-for- heat.
Setpoint:
this is the active setpoint. This temperature is the
result of Outdoor Air Reset, Setback and Domestic
Hot Water (DHW) selections.
i
<
Boiler 1 Active
180 F Fault
180 F
Rate 0%
Supply
Setpoint
Priority: Central Heat
Status: Standby
Rate:
The rate % value is equal to the actual fan speed
divided by the maximum fan speed.
Priority:
The selected Priority is shown. Available Priorities
are: Standby (no call for heat is present), Sequencer
Control, Central Heat, Domestic HW, Frost
Protection or Warm Weather Shutdown.
Status:
Information found at the
bottom of the Status screen
and on the Home screen.
Table 26 shows each status
and the action the control
takes during the condition.
i
Trends
<
Flame
2.5 hour trend
Supply / Return
Flame
5 minute trend
Firing Rate
>
Rate Limit:
The “ ” symbol appears to the right
of the Rate % when firing rate is
limited or overridden in any way.
During the start-up and shutdown
sequence it is normal for the rate to be
overridden by the purge and light-off
requirements. When a rate limit is the
result of boiler protection logic the
“ ” symbol blinks and becomes a
screen link
>
Data Logging
Real time graphic trends allow users to observe process
changes over time providing valuable diagnostic
information. For example, flame current performance
over start up periods and varying loads can be an indication
of gas supply issues. Additionally, supply and return
temperature dual pen trends brings a focused look at
heat exchanger and pump performance. For example,
studying a differential temperature trend may indicate
pump speed settings need to be changed.
<
Boiler Cycles/Hours
Boiler Cycles
2000
Run Time Hours
800
>
Cycles and Hours
Boiler cycles and hours are used to monitor the
boilers overall compatibility to the heating load.
Excessive cycling compared to run time hours
may be an indication of pumping, boiler sizing or
adjustment issues.
81
X. Operation F. Viewing Boiler Status (continued)
1. Status Screens (continued)
i
<
i
Pump Status/Cycles
System On
Boiler On
DHW Off
Frost Protection On
98
23
0
>
<
Heat Demand
Central Heat On
Domestic Hot Water Off
Sequence Master Off
Frost Protection Off
>
Exercise On
Pumping is a major part of any hydronic system. This screen
provides the status of the boiler’s demand to connected
pumps as well as the status of Frost Protection and pump
Exercise functions.
This screen provides the status of the boiler’s 4 possible
heat demands. When demand is off the Control has not
detected the call-for-heat.
2. Detail Screens
Detail screens are accessed by selected the “Detail”
button from the “Home” screen and provide in depth
operating parameter status such as “On Point”, “Off
Point” and Setpoint Source information.
i
i
Central Heat
Off Point + 5 F
Setpoint 180 F
On Point - 7 F
Supply
180 F
W
a
t
e
r
Firing Rate 22%
Setpoint: Outdoor Reset
Outdoor Reset
130
110
0
70
Setpoint 164 F
Outside Air 16 F
Status: Enabled
Outside Air
Demand detail screens are provided for Central Heat
(shown), DHW and Sequencer demands.
Outdoor Reset saves energy and improves home comfort
by adjusting boiler water temperature . This screen
presents the active reset curve. The curve shows the
relationship between outside air and outdoor reset
setpoint. The curve shown is adjustable by entering the
display’s adjust mode.
Figure 38: Detail Screens
82
180
X. Operation F. Viewing Boiler Status (continued)
3. Multiple Boiler Sequencer Screens
When the Sequence Master is enabled the following screens are available:
The Sequencer Status screen is selected by “pressing” “Status” button from the “Home” screen when Sequence Master is enabled.
Header:
measured header water temperature.
This is the temperature being used to
start, stop and fire boiler when there is
a call-for-heat.
Setpoint:
this is the active setpoint. This
temperature is the result of Outdoor
Air Reset, Setback and Domestic Hot
Water (DHW) selections.
i
Sequencer
132 F
180 F
Rate 100%
Header
Setpoint
<
>
Priority: Domestic Hot Water
Networked Boilers: 1 ,2 ,3 ,4 ,5 ,6 ,7 ,8
Rate:
The rate % value is equal to the
Sequence Master demand to the
individual boiler. Actual boiler firing
rate is found on the individual boiler
status pages.
Priority:
The selected Sequencer Priority is
shown. Available Priorities are:
Standby (no call for heat is present),
Central Heat, Domestic Hot Water,
Frost Protection or Warm Weather
Shutdown.
Networked Boiler Status:
Provides connected, start sequence and firing rate status information for all connected boiler addresses. The boiler number is
underlined if the boiler is running and blinks if the boiler has the start sequence in progress. For example the status for boiler
address 1 is provided as follows:
1 - Boiler 1 is connected to the network
1 - “Blinking underline” - boiler 1 is starting
1 - “Solid underline” - boiler 1 is running
The “Networked Boilers” screen is selected by “pressing” the “Detail” button from the “Home” screens and “pressing” Networked
Boilers” from the “Detail” screen.
Boiler Number:
Up to eight (8) boiler’s status is
shown
Lead Boiler:
Upon power up the lowest numbered
boiler becomes the lead boiler. The
lead boiler is the first to start and last
to stop. The lead boiler is
automatically rotated after 24 hours of
run time. Additionally, the lead is
rotated if there is a lead boiler fault.
i
Networked Boilers
Boiler 1
Lead
50% Firing
Boiler 2
50% Firing
Boiler 3
0 % Available
Boiler 4
0 % Available
Firing Rate:
Demanded firing rate is
provided.
Sequence Status:
Slave boiler status is provide as follows:
Boiler is ready and waiting to be started by the Sequencer Master.
Available:
Add Stage:
Boiler has begun the start sequence but has not yet reached the boiler
running status.
Running:
Boiler is running.
Boiler has left the network to service a DHW demand.
On Leave:
Recovering:
Boiler is in the process of returning to the network. For example, the
slave boiler is in the Postpurge state.
Note: The recovery time is normally 30 seconds. However, if the
slave boiler fails to start the recovery time increases from 30 seconds
to 5, 10 and 15 minutes.
Disabled:
Boiler has a lockout condition and is unable to become available to
the Sequencer Master.
83
X. Operation G. Changing Adjustable Parameters (continued)
G. Changing Adjustable Parameters
Adjust
1. Entering Adjust Mode
Active
Fault
Warning! Only Qualified
Technicians Should Adjust
Controls, Contact Your
Qualified Heating Professional
The Control is factory programmed
to include basic modulating boiler
functionality. These settings are password
protected to discourage unauthorized or
accidental changes to settings. User login is
required to view or adjust these settings:
- Press the “Adjust” button on the “Home”
screen.
- Press the “Adjust” button on the Adjust
Mode screen or Press Contractor for
service provider contact information.
- Press “Login” button to access password
screen.
- Press 5-digit display to open a keypad.
Enter the password (Installer Password
is 76) and press the return arrow to close
the keypad. Press the “Save” button.
- Press the “Adjust” button to enter
Adjustment mode.
For Service Contact:
CONTRACTOR NAME
ADDRESS LINE 1
ADDRESS LINE 2
PHONE NUMBER
Service Contact
i
Adjust
Login to Access
Adjustment Mode
Access Level: Installer
Password required
Installer Password = 76
i
Login
Press 5-digit display to
Input Password
i
076
1
2
3
4
5
ES
C
6
7
8
9
0
B
S
Adjust
Press 5-digit display to
Input Password
000
CL
R
Press Save to enter password
Save
After inputting the
password press
to enter password
Adjust
After password is Saved
These buttons access
Adjust mode screens
Figure 39: Adjust Mode Screens
2. Adjusting Parameters
Editing parameters is accomplished as follows:
i
Accept Value
Press the
button to confirm
newly edited value.
The value modified with the
increase and decrease buttons is
not accepted unless this button is
also pressed
84
<
Value to be edited
(blinks while editing)
Central Heat
CH Setpoint
180
F
>
Cancel edit
Edit Value
Press the
buttons to edit a
value. While editing a value it will blink
until it has been accepted or cancelled. A
value is also cancelled by leaving the
screen without accepting the value.
Press the
button to cancel
newly edited value and go back
to the original
X. Operation G. Changing Adjustable Parameters (continued)
2. Adjusting Parameters (continued)
From the “Home” screen select the Adjust button to access the adjustment mode screens shown below (if required, refer to
the previous page to review how to enter Adjustment mode):
System
Setup
Pump
Setup
Manual
Control
The following pages describe the
Control’s adjustable parameters.
Parameters are presented in the order
they appear on the Control’s Display,
from top to bottom and, left to right
Modulation
Setup
Contractor
Setup
- More -
Central
Heat
Outdoor
Reset
Sequence
Master
“Press”
System
Setup
button to access the following parameters:
Factory
Setting
Range /
Choices
Fahrenheit
Fahrenheit,
Celsius
4
0-14
Display Brightness
Display brightness is adjustable from 0 to 14.
8
0-14
Display Contrast
Display contrast is adjustable from 0 to 14.
Wired
Not Installed,
Wired
Wireless
Enabled
Parameter and Description
Temperature Units
The Temperature Units parameter determines whether temperature is represented in units of
Fahrenheit or Celsius degrees.
Outdoor Sensor Source
Not Installed Outdoor Sensor is not connected to the boiler, the sensor is not monitored for faults.
Wired
Outdoor Sensor is installed directly on the boiler terminal Strip-TB2.
Wireless
Outdoor sensor is installed and wireless.
Frost Protection
Disable
Frost Protection is not used.
Enable
Boiler and system circulators start and boiler fires when low outside air, supply and
return
temperatures are sensed as follows:
Enable/Disable
Device
Start
Stop
Started
Temperatures
Temperatures
Boiler & System
0 Secs
Disabled
70°F
Domestic
Hot Water
Remote
4-20mA
Sequence
Slave
0-900 Secs
Outside Air < 0°F (-18°C)
Outside Air > 4°F (-16°C)
Anti-Short Cycle Time
Anti-short cycle is a tool that helps prevent excessive cycling resulting from a fast cycling
Thermostat or Zone valves. It provides a minimum delay time before the next burner cycle. DHW
demand is serviced immediately, without any delay.
Warm Weather Shutdown Enable
Disable
Warm Weather Shutdown (WWSD) is not used.
Enable
The boiler will not be allowed to start in response to a central heat call for heat if the
Enable/Disable
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.
The boiler will still start in response to a Domestic Hot Water call for heat.
0-100°F
Warm Weather Shutdown Setpoint
The Warm Weather Shutdown (WWSD) Setpoint used to shutdown the boiler when enabled by the
“WWSD Enable” parameter.
85
X. Operation G. Changing Adjustable Parameters (continued)
2. Adjusting Parameters (continued)
WARNING
Asphyxiation Hazard. Boiler type is factory set and must match the boiler model. Only change the boiler
type setting if you are installing a new or replacement Control. The boiler type setting determines minimum
and maximum blower speeds. Incorrect boiler type can cause hazardous burner conditions and improper
operation that may result in PROPERTY LOSS, PHYSICAL INJURY OR DEATH.
“Press”
Modulation
Setup
Factory
Setting
button to access the following parameters:
Range /
Choices
Parameter and Description
Boiler Type
Boiler Size Setup
To verify the boiler size selection, a qualified technician should do the following:
1. Check boiler’s label for actual boiler size.
2. Set “Boiler Type” to match actual boiler size.
3. Select “Confirm”.
The Boiler Type parameter changes the minimum and maximum modulation settings. This
parameter is intended to allow a user to set the parameters in a spare part Sage2.1 Controller to a
particular boiler type.
Central Heat Maximum Modulation
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 home 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.
Domestic Hot Water (DHW) Max Modulation
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.
See Table
28
See Table 28
See Table
28
Minimum to
Maximum
Modulation
See Table
28
Minimum to
Maximum
Modulation
See Table
28
Minimum
- 100 to
Maximum
Minimum Modulation
This parameter is the lowest modulation rate the Control will go to during any call for heat.
See Table
28
See Table 28
Lightoff Rate
This is the blower speed during ignition and flame stabilization periods. Non-adjustable on
models APX625 and APX725.
Table 28: Parameters Changed Using the Boiler Type Parameter Selections:
Sage2.1 Control Repair Part
Altitude
Boiler Type
Maximum Light-off Rate (RPM)
Maximum Modulation Rate
(RPM)
Minimum Modulation Rate
(RPM)
Absolute Maximum Modulation
Rate (RPM)
104472-01 104472-04 105008-02 105008-01 105008-02 105008-01
0 - 4500 ft.
0 - 2000 ft.
104472-04
0 - 4500 ft.
425
-07
525
-07
625N
-02
625P
-02
725N
-02
725P
-02
825N
-05
825P
-05
4000
4000
2500
4000
2500
4000
4000
4000
7600
5900
5050
4800
4350
4400
5200
5150
2100
1400
1600
1600
1400
1450
1200
1200
8500
6550
5900
6300
5500
5850
5900
5600
NOTE: Maximum Modulation Rates are designed for 100% nameplate rate at 0°F (-18°C) combustion air. Contact factory before
attempting to increase the Maximum Modulation Rate.
86
X. Operation G. Changing Adjustable Parameters (continued)
“Press”
Pump Setup
Factory Setting
Central Heat,
Optional Priority
button to access the following parameters:
Range / Choices
Never,
Any Demand,
Central Heat,
No Priority,
Central Heat,
Optional Priority
Any Demand
Primary
Loop Pipe
IWH
Any Demand,
Central Heat, off
DHW demand
Never,
Primary Loop
Piped IWH,
Boiler Piped IWH
Parameter and Description
System Pump run pump for:
Activates the system pump output according to selected function.
Never: Pump is disabled and not shown on status screen.
Any Demand: Pump Runs during any call for heat.
Central Heat, No Priority: Pump Runs during central heat and frost protection call for
heat. Pump does not start for a DHW call for heat and
continues to run during Domestic Hot Water Priority.
Central heat, Optional
Priority:
Pump Runs during central heat and frost protection call for
heat. Pump does not start for a DHW call for heat and will be
forced off if there is a DHW call for heat and Domestic Hot
Water Priority is active.
Boiler Pump run pump for:
Activates the boiler pump output according to selected function.
Any Demand:
Pump Runs during any call for heat.
Central Heat, off DHW
demand:
Make sure indirect water heater and DHW circulator are sized
to maintain flow through boiler within limits shown in Table 12.
Pump Runs during central heat and frost protection call for
heat. Pump does not start for a DHW call for heat and will
be forced off if there is a DHW call for heat and Domestic Hot
Water Priority is active.
Domestic Pump run pump for:
Activates the Domestic pump output according to selected function.
Never:
Pump is disabled and not shown on status screen.
Primary Loop Piped IWH: Pump Runs during domestic hot water call for
heat. Domestic Hot Water 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 12.
Pump Runs during domestic hot water call for heat. Pump is
forced off during a central heat call for heat when Domestic
Hot Water Priority “disabled” is selected and when Domestic
Hot Water Priority “enable” has been selected and the DHW
call for heat has remained on for longer than 1 hour (priority
protection time).
Example Pump Parameter selections:
Single boiler with no Indirect Water Heater
Parameter Selections:
System Pump= “any demand”
Boiler Pump = “any demand”
DHW Pump = “never”
Explanation:
This piping arrangement only services
central heat. When there is any demand both boiler and system pumps
turn on.
87
X. Operation G. Changing Adjustable Parameters (continued)
Example Pump Parameter selections (continued):
Single boiler Indirect Water Heater Piped to Primary, Optional Domestic Hot Water Priority.
Parameter Selections:
System Pump= “Central Heat ,
Optional Priority”
Boiler Pump = “any demand”
DHW Pump = “Primary Loop Piped IWH”
DHW Priority Enable is optional
Explanation:
This piping arrangement permits the
system pump to run or not run when
there is a domestic hot water call for
heat. Domestic hot water priority is
optional. It is permissible for the
domestic and system pumps to run at
the same time. The boiler pump must
run for every call for heat.
Multiple Boilers with Boiler Piped IWH, System and DHW Wired to Master
Sequencer Master
(Boiler 1)
Boiler 2
Wiring locations:
Thermostat
X
DHW call for heat
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 12.
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.
88
X. Operation G. Changing Adjustable Parameters (continued)
Example Pump Parameter selections (continued):
Multiple boilers IWH Piped to Primary, Optional Domestic Hot Water Priority
Sequencer Master
(Boiler 1)
Boiler 2
Wiring locations:
Thermostat
X
DHW call for heat
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.
Multiple Boilers, IWH piped to primary, system pump required to run for any call for heat
Sequencer Master
(Boiler 1)
Boiler 2
Wiring locations:
Thermostat
X
DHW call for heat
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.
89
X. Operation G. Changing Adjustable Parameters (continued)
“Press”
Contractor
Setup
button to access the following parameters:
i
Contractor Name
For Service Contact:
Bill Smith
12 Victory Lane
Plainview, New York
516 123-4567
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Bill Smith
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Factory Setting
Range / Choices
Contractor Name
User defined
Contractor Name
Address Line 1
User defined
Contractor Address Line 1
Address Line 2
User defined
Contractor Address Line 2
Phone
User defined
Contractor Phone
“Press”
Manual
Control
Parameter and Description
button to access the following screen:
The Manual Speed Control speed screen allows the technician to set firing rate at low or high speed for combustion testing.
i
Manual Speed Control
0 RPM
0%
Status Auto
press to change mode
Low
“Press” “Low” to select
manual firing rate control
and Minimum firing rate %
90
High
Auto
“Press” “High” to select
manual firing rate control
and Central Heat
Maximum firing rate %
NOTE
Selecting “Low” or “High”
locks (manual mode) firing
rate at min or max Rate %.
After combustion testing select
“Auto” to return the boiler to
normal operation.
Press “Auto”
to return
firing rate to
Automatic
Mode
X. Operation G. Changing Adjustable Parameters (continued)
“Press”
Factory
Setting
Central
Heat
button to access the following parameters:
Range / Choices
Parameter and Description
180°F
80°F to 190°F
Central Heat Setpoint
(82.2°C) (26.7°C to 87.8°C) Target temperature for the central heat priority. Value also used by the outdoor air reset function.
Central Heat Thermostat “Sleep” or “Away” Setback Setpoint
Thermostat setback setpoint is used when the EnviraCOM thermostat is in “leave” or “sleep”
modes and sensed at E-COM terminals D, R, and C. When setback is “on” the thermostat set170°F
80°F to 190°F
back setpoint shifts the reset curve to save energy while home is in a reduced room temperature
(76.7°C) (26.7°C to 87.8°C) mode. The reset curve is shifted by the difference between the High Boiler Water Temperature
and the Thermostat Setback Setpoint. Honeywell VisionPro IAQ part number TH9421C1004 is a
“setback” EnviraCOM enabled thermostat. When connected, it allows boiler water setback cost
savings.
5°F
(2.8°C)
2°F to 10°F
(1.1°C to 5.6°C)
Central Heat Diff Above
The boiler stops when the water temperature rises ‘Diff Above’ degrees above the setpoint.
7°F
(3.9°C)
2°F to 30°F
(1.1°C to 17°C)
Central Heat Diff Below
The boiler starts when the water temperature drops ‘Diff Below’ degrees below the setpoint.
3
“Press”
Factory
Setting
1 to 5
Domestic
Hot Water
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 “Diff 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.
button to access the following parameters:
Range / Choices
Parameter and Description
Domestic Hot Water Setpoint
170°F
80°F to 190°F
The Domestic Hot Water (DHW) Setpoint parameter is used to create a minimum boiler water
(76.7°C) (26.7°C to 87.8°C) temperature setpoint that is used when DHW heat demand is “on”.
When the DHW heat demand is not “on” (the contact is open or not wired) this setpoint is ignored.
Domestic Hot Water Thermostat “Sleep” or “Away” Setback Setpoint
Thermostat setback setpoint is used when the EnviraCOM thermostat is in “leave” or “sleep”
160°F
80°F to 190°F
modes and sensed at E-COM terminals D, R, and C. When setback is “on” the thermostat set(71.1°C) (26.7°C to 87.8°C)
back setpoint shifts the DHW setpoint to lower the DHW temperature and to save energy while
home is in a reduced room temperature mode.
5°F
(2.8°C)
2°F to 10°F
(1.1°C to 5.6°C)
Domestic Hot Water Diff Above
The boiler stops when the water temperature rises ‘Diff Above’ degrees above the setpoint.
7°F
(3.9°C)
2°F to 30°F
(1.1°C to 17°C)
Domestic Hot Water Diff Below
The boiler starts when the water temperature drops ‘Diff Below’ degrees below the setpoint.
Enable
Enable Disable
Domestic Hot Water Priority (DHWP)
When Domestic Hot Water Priority is Enabled and Domestic Hot Water (DHW) heat demand is
“on” the DHW demand will take “Priority” over home 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 DHW Priority. Priority protection time is provided to
end DHWP in the event of a failed or excessive long DHW demand.
60
Minutes
30 to 120 Minutes
3
1 to 5
Priority Time
When DHWP is Enabled the Priority Time Parameter appears and is adjustable.
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 “Diff 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.
91
X. Operation G. Changing Adjustable Parameters (continued)
“Press”
Outdoor
Reset
Factory
Setting
Enabled
button to access the following parameters:
Range / Choices
Enable Disable
Parameter and Description
Outdoor Reset Enable
If an outdoor sensor is installed and Outdoor Reset is Enabled, the boiler will automatically
adjust the heating zone set point temperature based on the outdoor reset curve in Figure
40. The maximum set point is defined by the Central Heat Setpoint [factory set to 180°F
(82.2°C)] when the outdoor temperature is 0°F (-18°C) or below. The minimum set point
temperature shown is 130°F (54.4°C) [adjustable as low as 80°F (26.7°C)] when the
outdoor temperature is 50°F (10°C) or above. As the outdoor temperature falls the supply
water target temperature increases. For example, if the outdoor air temperature is 30°F,
(-1.1°C) the set point temperature for the supply water is 150°F (65.6°C).
Disable Enable 0°F
(-18°C)
-40°F to 100°F
(-40°C to 37.8°C)
70°F
(21.1°C)
32°F to 100°F
(0°C to 37.8°C)
Low Outdoor Temperature
The Low Outdoor Temperature parameter is 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.
High Outdoor Temperature
The High Outdoor Temperature parameter is the outdoor temperature at which the Low
Boiler Water Temperature is supplied. This parameter is typically set to the desired building
temperature.
110°F
(43.3°C)
Low Boiler Water Temperature
70°F to 190°F
The Low Boiler Water Temperature parameter is the operating setpoint when the High
(21.1°C to 87.8°C) Outdoor Temperature is measured. If the home feels cool during warm outdoor conditions,
the Low Boiler Water Temperature parameter should be increased.
130°F
(54.4°C)
Minimum Boiler Temperature
The Minimum Boiler Temperature parameter sets a low limit for the Reset setpoint. Set this
80°F to 190°F
parameter to the lowest supply water temperature that will provide enough heat for the type
(26.7°C to 87.8°C)
radiation used to function properly. Always consider the type of radiation when adjusting
this parameter.
0 Minutes
92
Do Not Calculate setpoint based on outdoor temperature
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.
0-1800 Seconds
(0-30 Minutes)
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 home 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.
X. Operation G. Changing Adjustable Parameters (continued)
Central Heat Setpoint
Low Outside Air Temp
=180 F & 0 F
200
195
Boost Maximum Off Point
= Central Heat Setpoint
minus Diff Above
190
185
180
175
170
160
155
150
145
140
135
10 F
Hot Water Setpoint
165
130
Default Boost Outdoor Air Reset Setpoint
(Shown with thin lines, typical)
(Reset setpoint increased by 10 F every
20 minutes that demand is not satisfied.
Boost Time is field selectable
between 0 to 30 minutes)
TOD Setback Setpoint
Default = 170 F
Minimum Water Temperature
Default = 130 F
125
Default Outdoor Air Reset Setpoint
(Shown Bold)
120
115
Low Boiler Water Temp
Default = 110 F
High Outside Air Temp
Default = 70 F
110
Outdoor Air Temperature
-20 -15 -10
-5
0
5
10
15
20
25
30
35
40
45
50
55
60
65
70 75
Figure 40: Outdoor Reset Curve
Central Heat
Setpoint
Heating Element Type
Central Heat
Setpoint
Heating Element Type
180°F to 190°F
(82.2°C to 87.8°C)
Fan Coil
100°F to 140°F
(37.8°C to 60°C)
In Slab Radiant High
Mass Radiant
160°F to 190°F
(71.1°C to 87.8°C)
Convection
Baseboard
Fin Tube
Convective
130°F to 160°F
(54.4°C to 71.1°C)
Staple-up Radiant
Low Mass Radiant
130°F to 160°F
(54.4°C to 71.1°C)
Radiant
Baseboard
140°F to 160°F
(60°C to 71.1°C)
Radiators
93
X. Operation G. Changing Adjustable Parameters (continued)
“Press”
Factory
Setting
Remote
4-20mA
button to access the following parameters:
Range /
Choices
Parameter and Description
Central Heat Modulation Source
This parameter enables the 4-20mA input to control firing rate and the thermostat input to control boiler on/off
Local,
demand directly without using the internal setpoint. The 4-20mA selection is used to enable a remote multiple boiler
Local
4-20mA
controller to control the Sage2.1 Control:
Local:
4-20mA Input on Terminal 9 & 10 is ignored.
4-20mA
4-20mA Input on Terminal 9 & 10 is used to control firing Rate % directly.
Central Heat Setpoint Source
Sets the remote (Energy Management System) control mode as follows:
Local,
Local
Local:
Local setpoint and modulation rate is used. 4-20mA input on Terminal 9 & 10 is ignored.
4-20mA
4-20mA
4-20mA Input on Terminal 9 & 10 is used as the temperature setpoint. The following two
parameters may be used to adjust the signal range.
80°F (26.7°C) - Central Heat 4-20mAdc Setup, 4 mA Water Temperature*
130°F
Central Heat Sets the Central Heat Temperature Setpoint corresponding to 4mA for signal input on terminal 9 & 10. Current
(54.4°C)
Setpoint
below 4mA is considered invalid, (failed or incorrect wired input).
80°F (26.7°C) - Central Heat 4-20mAdc Setup, 20 mA Water Temperature*
180°F
Central Heat Sets the Central Heat Temperature Setpoint corresponding to 20mA for signal input on terminal 9 & 10. Current
(82.2°C)
Setpoint
above 20mA is considered invalid, (failed or incorrect wired input).
* Only visible when Central Heat Setpoint Source is set to 4-20mA.
“Press”
Sequence
Master
button to access the following parameters:
Factory
Setting
Range / Choices
Disable
Enable,
Disable
Boiler
Piped
Boiler Piped,
Primary Piped
Disabled
Enable,
Disable
120 Secs
120 - 1200 Secs
195°F
(90.6°C)
Central Heat
Setpoint,
195°F (90.6°C)
50%
50% - 100%
3
1-5
“Press”
Sequence
Slave
Master Enable/Disable
The Sequencer Master Enable/Disable is used to “turn on” the Multiple Boiler Controller. Warning! enable
ONLY one Sequence Master.
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
The Sequencer to immediately start two boilers for a DHW call for heat. Used when DHW is the largest
demand. Only visible when primary piped IWH is selected.
Boiler Start Delay
Slave boiler time delay after header temperature has dropped below the setpoint minus “Diff below” setpoint.
Longer time delay will prevent nuisance starts due to short temperature swings.
Stop All Boilers Setpoint
When this temperature is reached all boilers are stopped. This setpoint allows the Sequencer to respond to
rapid load increases.
Base Load Common Rate
To maximize condensing boiler efficiency, the 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%.
Response Speed
This parameter adjusts the Sequence Master 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 “Diff
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.
button to access the following parameters:
Factory
Setting
Range / Choices
None
1-8
Normal
Use Boiler First,
Normal,
Use Boiler Last
94
Parameter and Description
Parameter and Description
Boiler Address
Each boiler must be given a unique address. When ”Normal” slave selection order is used, the boiler address
is used by the Master Sequencer as the boiler start order. The boiler address is also the Modbus Address
when a Energy Management System is connected.
Slave Selection Order
“Use Boiler First”; places the Slave in the lead permanently.
”Normal”; firing order follows boiler number (1,2,3,..) order.
”Use Boiler Last”; places the slave last in the firing order.
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:
•
•
•
•
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.
95
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 printed on the back of this manual. 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.
96
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 rodent 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.
3. Inspect the flue temperature sensor cap to verify that
it is free from leakage and deterioration. Call the
service technician to make repairs, if needed.
4. 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 34 “Operating Instructions”.
3. Inspect the wiring to verify the conductors are in
good condition and attached securely.
97
XI. Service and Maintenance (continued)
9. Inspect the condensate trap to verify it is open and free
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
41 “Igniter Electrode Gap” for details.
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 the flue temperature sensor cap to verify that
it is free from leakage and deterioration. Replace if
needed.
11. 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.
12. Check for vent and air intake terminal for obstructions
and clean as necessary. Check rodent screens in vent
and air intake terminations to verify they are clean and
free of debris.
13. Reinstall the burner/blower/gas valve assembly and
secure with M6X1 hex flange nuts.
14. Reconnect any wiring which has been disconnected.
15. Verify that the system pH is between 7.5 and 9.5.
16. Inspect the heating system and correct any other
deficiencies prior to restarting the boiler.
17. Follow Section IX “System Start-up” before leaving
installation.
Figure 41: Igniter Electrode Gap
5. To gain access to boiler burner and combustion chamber,
18. Perform the combustion test outlined in Section IX
“System Start-up”.
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.
D.Recommended Heating System Water
Treatment Products:
6. Inspect the assembly for lint and dust presence. If
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)
Follow manufacturer application procedure
for proper heating system/boiler cleaning and
preventive treatment.
Above referenced products are available
from Cookson Electronics Company, 4100
Sixth Avenue, Altoona, PA 16602, Tel: (814)
946-1611 and/or selected HVAC distributors.
Contact Thermal Solutions for specific details.
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
prohibited. Do not use any cleaning agents or solvents. If
insulation disc has signs of damage, it must be replaced.
98
1. System Cleaning and Conditioning:
XI. Service and Maintenance (continued)
iii. Equivalent system water treatment products
may be used in lieu of products referenced
above.
2. System Freeze Protection:
a. The following heating system freeze protection
products are recommended for Apex boilers:
i. Fernox™ Protector Alphi 11 (combined
antifreeze and inhibitor).
Follow manufacturer application procedure
to insure proper antifreeze concentration and
inhibitor level.
Above referenced product is available from
Cookson Electronics Company, 4100 Sixth
Avenue, Altoona, PA 16602, Tel: (814) 9461611 and/or selected HVAC distributors.
Contact Thermal Solutions for specific details.
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.
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:
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 42
“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.
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.
Figure 42: Condensate Overflow Switch Orientation
99
XI. Service and Maintenance (continued)
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 42 “Condensate
Overflow Switch Orientation” for details.
k. Insure that pressure switch hose is reconnected to
the trap.
Outdoor Air Temperature Sensor
Temperature versus Resistance
(P/N 102946-01)
(10kOhm NTC Sensor)
Outdoor Temperature
100
l. Restore power supply to boiler. Fill up the trap
(see Section V “Condensate Disposal”) and
verify the switch operation.
Header Temperature Sensor
Temperature versus Resistance
(P/N 101935-01 or 103104-01)
(10kOhm NTC Sensor), Beta of 3950
Temperature
°C
Ohms of
Resistance
32
0
32648
50
10
19898
68
20
12492
77
25
10000
86
30
8057
104
40
5327
122
50
3602
140
60
2488
158
70
1752
176
80
1256
194
90
916
212
100
697
248
120
386
°F
Supply, Return and Stack Temperature Sensor
Temperature versus Resistance
°F
°C
Ohms of
Resistance
-20
-28.9
106926
-10
-23.3
80485
°F
°C
Ohms of
Resistance
0
-17.8
61246
32
0
36100
10
-12.2
47092
50
10
22790
20
-6.7
36519
68
20
14770
30
-1.1
28558
77
25
12000
40
4.4
22537
86
30
9810
(12kOhm NTC Sensor), Beta of 3750
Temperature
50
10.0
17926
104
40
6653
60
15.6
14356
122
50
4610
70
21.1
11578
140
60
3250
70
2340
80
1710
76
24.4
10210
158
78
25.6
9795
176
80
26.7
9398
194
90
1270
90
32.2
7672
212
100
950
100
37.8
6301
230
110
730
248
120
560
110
43.3
5203
120
48.9
4317
XII. Troubleshooting
WARNING
Electrical Shock Hazard. Turn off power to boiler before working on wiring.
A. Troubleshooting problems where no error code is displayed.
Condition
Possible Cause
Boiler not responding to call for heat, “Status” and
“Priority” show “Standby”.
Boiler not responding to a call for heat, “Status”
shows “Standby” and “Priority” shows Central Heat
or Domestic Hot Water.
Boiler Running but System or Boiler Circulator
is not running
Home is cold during mild weather days
Home is cold during cold weather days
Boiler is not seeing call for heat. Check thermostat or zone wiring for loose connection,
miswiring, or defective thermostat/zone control.
Boiler is not firing, temperature is greater than setpoint. Water flow through boiler primary
loop non-existent or too low.
• Check wiring for loose connection, miswiring. Flow switch is defective and needs
replacement.
• When there is a Domestic Hot Water Heat Request the System or Boiler pumps will be
forced “off” when there “Run Pump for” parameter is set to “Central heat, off DHW
demand” or “Central Heat, Optional Priority”. This has been set to allow all of the heat
to be provided for fast indirect water heater recovery. After one hour of “priority
protection” or the end of the Domestic Hot Water Heat Request the system and boiler
pumps will be free to run.
• Increase Low Boiler Water Temperature parameter 5°F (2.8°C) per day.
• Increase High Boiler Water Temperature parameter 5°F (2.8°C) per day
B. Display Faults:
Faults are investigated by selecting the “Help” button from the “Home” screen. When a fault is active the “Help” button flashes
and the home screen turns a red color. Continue to select flashing buttons to be directed to the Fault cause.
i
Home Screen
Status
Detail
Help
Boiler **00FF
024 F
Sensor
Fault
Standby
Energy Save On
Adjust Max Efficiency On
i
i
Active Faults
Communication
Fault
Soft Lockout
(Hold)
Hard
Lockout
Lockout
History
Sequencer
Setup
Limit String
Status
Sensor
Status
Service
Contract
Boiler Size
Setup
Rate Limit
Status
Reset
Active Fault Screen
Help Screen
Figure 43: Help Menu
Indication
Condition
Possible Cause
Display Completely Dark
Fan off, LWCO lights off, no green power
light on Control
No 120 VAC
Power at Boiler
Check breaker and wiring between breaker panel and boiler.
Display Completely Dark, Fan running
No 24 VAC
Power to Control
Blinking Green power light on Control
Control
Fault
Display Completely Dark but Boiler fires
No 5 VDC
Power to Display
- Loose/defective 120Vac connection wiring between boiler J-Box and
transformer and/or transformer and Control.
- Loose 24 Vac connection wiring between transformer and Control.
- 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 reconnected green light will begin to flash.
- Loose 5 VDC connection wiring between display and Control
- Defective display.
**00FF
Display lost
communication
with control
Adjustment Mode
Password Timeout
ER0011
-
Loose or defective display harness
Defective Display
Defective Control
The Control and Display are NOT defective. The password has timed out.
Simply cycle power to the Display to restore operation.
101
XII. Troubleshooting (continued)
C. Help Screen Faults
Indication
Condition
Sequencer
Setup
Fault
Sequencer
Setup
Flashing
Boiler
Size
Fault
Boiler Size
Setup
Flashing
Possible Cause
This alarm is active if the slave boiler has lost communication with the Sequence Master. Check
the following:
- RJ 45 peer-to-peer network disconnected
- Sequencer Master was Enabled and then Disabled
- Master’s Boiler has been powered down.
- To clear fault restore communication or cycle power
WARNING!
Boiler size setting may not match actual boiler size.
The Boiler size setting determines min, max and light-off blower speeds. Incorrect boiler size can
cause hazardous burner conditions and improper operation that may result in PROPERTY LOSS,
PHYSICAL INJURY, OR DEATH.
Refer to Page 86 for boiler size setting instructions.
D. Help Screen Diagnostic Features
Indication
i
Possible Cause
Lockout History 1 of 10 (newest)
<
Supply High Limit
>
When happened Current
Running
Lockout
Status
Run Time Hour
50
50
For Service Contact:
CONTRACTOR NAME
CONTRACTOR ADDRESS 1
CONTRACTOR ADDRESS 2
PHONE NUMBER
Lockout History is stored in a first-in, first-out basis. Each History file is stored with boiler run hour of when the
lockout occurred.
The “When happened” and “Current” provide:
- “Current” is the run hour and status the boiler just finished.
- “When happened” is the run hour and status when the lockout occurred.
The user is given the contact information of the responsible service provider. Refer to page 90 for data entry
instructions.
E. Active Fault Screen Faults
Indication
Limit String Status
i
Limit String Status
Condition
Possible Cause
Limit String
Fault
The Limit String Status screen shows the faulty safety limit and/or open flow switch. A contact icon,
either “open” or “closed”, graphically represents each safety limit and flow switch. The “closed”
contact icon is steady; the “open” contact icon is blinking. For example, the screen shown to the
left illustrates a “closed” Air Pressure Switch contact and an “open’ Auto Reset High Limit contact.
The Auto Reset High Limit is causing the boiler to stop firing.
NOTE: Since the limit string items are wired in series, all limits downstream of the “open” limit will
also appear on the screen as “open” (blinking) icons regardless of whether or not they are actually
open.
Condensate (Gas Press Switch,
Air
Auto
Float Switch
LWCO,
Press Reset (& Thermal Link External Hi Limit
Switch Hi Limit on Size > 210) When provided)
Sensor Status
i Supply Sensor
180 F
Return Sensor 768 F
Stack Sensor 024 F
Outdoor Sensor 45 F
Header Sensor
4-20mA Input 4 mA
Normal
Shorted
Open
Normal
None
Normal
Sensor
Fault
When a sensor fails “opened” or “shorted” the value is changed to reverse video (background
black and value white) “024” or “768” respectively to indicate that there is a fault with the sensor.
Rate Limit
i
Rate Limits
Active Rate Limiter:
High Stack Temp Rate Limit
Active Rate Override:
Burner Control Rate Override
102
The Sensor Status screen shows the status of all sensors. Possible states include:
None:
Feature requiring this sensor has not been selected.
Normal: Sensor is working normally.
Shorted: Sensor is shorted or is defective.
Open: There is a break in the wiring between the Control and the sensor or the sensor is
defective
Out of Range: Sensor is defective or is being subjected to electrical noise.
Unreliable:
Sensor is defective or is being subjected to electrical noise.
High Stack
Temperature
Rate Limit
The following messages appear when the firing rate is limited or reduced to help avoid a lockout.
Refer to lockout section for potential corrective action.
- High Stack Temperature Limit
- High Supply Temperature Limit
- High Differential Temperature Limit
The following messages appear as part of a normal start and stop sequence:
- Minimum Modulate (normal start/stop sequence)
- Forced Modulation (normal start/stop sequence)
- Burner Control Rate (normal start/stop sequence)
- Manual Firing Rate ( User selection)
XII. Troubleshooting (continued)
F. Troubleshooting problems where a Soft Lockout Code is displayed. When a soft lockout occurs, the
boiler will shut down, the display will turn red and the “Help” button will “blink”. Select the “blinking” “Help” button to
determine the cause of the soft lockout. The boiler will automatically restart once the condition that caused the lockout is
corrected.
Soft Lockout Codes Displayed
Lockout
Number
Condition
1
Anti Short Cycle
Minimum time between starts has not been reached.
Normal delay used to avoid excessive cycles.
2
Boiler Safety Limit
Open
Boiler Safety Limit wired to terminals J6-1, 2 or 3
OPEN:
• Condensate Trap Float Switch
contact open.
• Thermal Link Switch contact open.
• Burner Door Thermostat with manual reset
contact open.
• Air Pressure Switch contact open.
• Auto Reset High Limit contact open.
Possible Cause
•
•
•
•
•
•
•
•
Loose wiring to limit device.
Auto Reset Supply high limit sensor detected temperature in excess of 200°F.
Defective Auto Reset Supply High Limit Switch.
Plugged Condensate Trap - also check to ensure boiler is level.
Thermal Link Switch blown due to temperature rise above 604°F (318°C).
Burner Door Thermostat with manual reset contact open due to temperature rise
above 500°F (260°C) - check the cause of overheating (burner door insulation, loose
mounting, etc.).
Air Pressure Switch contact open - check for blocked vent.
See possible causes for “Hard Lockout 4”.
NOTE
Block Vent Special Note
Before a call for heat the air pressure switch is closed. When there is a call for heat
with a blocked vent the air pressure switch will open (due to excessive pressure of the
blower against a blocked flue pipe) after the blower starts. The control stops the start
sequence and stops the blower. After the blower stops the pressure switch re-closes
and the cycle continues. The displays shows the cause of trip for only the time the
pressure switch is open.
3
Boiler Safety Limit
Open
Boiler Safety Limit, or External Limit wired to
terminals J5-1 OPEN:
• Jumper for External Limit wired to terminals 11
and 12 or device connected to it open.
• Jumper for Flow Switch or device connected to
it open.
• Jumper for Low Gas Pressure Switch or device
connected to it open.
•
•
•
•
•
•
•
See possible causes for “Hard Lockout 4”.
Loose wiring to limit device.
External Limit defective or jumper not installed.
Low Gas Pressure Switch contact open (if installed).
Flow switch not installed and jumper missing.
No flow or insufficient flow through boiler loop or flow switch defective.
If neither yellow or green light is on, check LWCO harness.
7
Return sensor fault
Shorted or open return temperature sensor.
•
•
Shorted or mis-wired return sensor wiring.
Defective return sensor.
8
Supply sensor fault
Shorted or open supply temperature sensor.
•
•
Shorted or mis-wired supply sensor wiring.
Defective supply sensor.
9
DHW sensor fault
Shorted or open Domestic Hot Water (DHW)
temperature sensor.
•
•
Shorted or mis-wired DHW sensor wiring.
Defective DHW sensor.
10
Stack sensor fault
Shorted or open flue gas (stack) temperature sensor.
•
•
Shorted or mis-wired stack sensor wiring.
Defective stack sensor.
•
•
•
•
•
•
•
11
Ignition failure
Model APX425 flame failure after 5 tries to restart.
•
No gas pressure.
Gas pressure under minimum value shown on rating plate.
Gas line not completely purged of air.
Defective Electrode.
Loose burner ground connection.
Defective Ignition Cable.
Defective gas valve (check for 24 Vac at harness during trial for ignition before
replacing valve).
Air-fuel mixture out of adjustment - consult factory.
•
•
Shorted or mis-wired flame rode wiring.
Defective flame rod.
•
Inadequate boiler water flow. Verify that circulator is operating and that circulator
and piping are sized per Section VI of this manual.
13
Flame rod
shorted to ground
Flame rod shorted to ground
14
DT inlet/outlet high
Temperature rise between supply and return is too
high.
15
Return temp higher
than supply
•
The Control is reading a return sensor temperature
•
higher than the supply sensor temperature. Condition
must be present for at least 75 seconds for this error
•
code to appear.
•
16
Supply temp has risen Supply water temperature has risen too quickly.
too quickly
17
Blower speed not
proved
•
•
•
Flow through boiler reversed. Verify correct piping and circulator orientation.
No boiler water flow. Verify that system is purged of air and that appropriate valves
are open.
Sensor wiring reversed.
Supply or return sensor defective.
See possible causes for “Hard Lockout 4”.
Inadequate boiler water flow.
Verify that circulator is operating and that circulator and piping are sized per
Section VI of this manual.
Normal waiting for blower speed to match purge and
light-off setpoint.
103
XII. Troubleshooting (continued)
G. Troubleshooting problems where a Hard Lockout Code is displayed. When a hard lockout occurs, the
boiler will shut down, the display will turn red and the “Help” button will “blink”. Select the “blinking” “Help” button to
determine the cause of the Hard Lockout. Once the condition that caused the lockout is corrected, the boiler will need to be
manually reset using the Reset button on the “Active Fault” display or located on the Sage2.1 Control.
Hard Lockout Codes Displayed
Lockout Number
Condition
Possible Cause
•
4
Supply high limit
Sage2.1 supply sensor detected
temperatures in excess of 210°F.
•
•
•
5
DHW high limit
Sage2.1 DHW sensor detected
temperatures in excess of Setpoint.
6
Stack High limit
Sage2.1 Flue gas (Stack) sensor detected
temperatures in excess of 204°F (95.6°C).
•
•
DHW load at time of error was far below the minimum firing
rate of the boiler.
Control system miswired so that boiler operation is permitted
when no DHW are calling.
•
•
•
Heat exchanger needs to be cleaned.
Boiler over-fired.
Air-fuel mixture out of adjustment - consult factory.
A flame signal was present when there
should be no flame.
•
Defective gas valve - make sure inlet pressure is below
maximum on rating plate before replacing valve.
18
Light off rate proving failed
Blower is not running at Light-off rate
when it should or blower speed signal not
being detected by Sage2.1.
•
•
•
Loose connection in 120 VAC blower wiring.
Loose or miswired blower speed harness.
Defective blower
19
Purge rate proving failed
Blower is not running at Purge rate when
it should or blower speed signal not being
detected by Sage2.1.
•
•
•
Loose connection in 120 VAC blower wiring.
Loose or miswired blower speed harness.
Defective blower
20
Invalid Safety Parameters
Unacceptable Sage2.1 control Safety
related parameter detected.
Safety Parameter verification required. Contact factory.
Unacceptable Sage2.1 control Modulation
related parameter detected.
Reset the control.
Safety related parameter change has
been detected and a verification has not
been completed.
Safety related Sage2.1 control parameter has been changed and
verification has not been performed.
12
Flame detected out of sequence
21
Invalid Modulation Parameter
22
Safety data verification needed
23
24VAC voltage low/high
Sage2.1 control 24Vac control power is
high or low.
•
•
•
•
•
•
Loose connection in 24Vac VAC 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.
Loose or defective gas valve harness. Check electrical
connections.
Defective gas valve (check for 24 Vac at harness during trial
for ignition before replacing valve).
24
Fuel Valve Error
Power detected at fuel valve output when
fuel valve should be off.
25
Hardware Fault
Internal control failure.
•
Reset the control. If problem reoccurs, replace the Sage.
26
Internal Fault
Internal control failure.
•
Reset the control. If problem reoccurs, replace the Sage.
•
•
•
•
•
•
•
No gas pressure.
Gas pressure under minimum value shown on rating plate.
Gas line not completely purged of air.
Defective Electrode.
Loose burner ground connection.
Defective Ignition Cable.
Defective gas valve (check for 24 Vac at harness during trial
for ignition before replacing valve).
Air-fuel mixture out of adjustment - consult factory.
27
Ignition failure
Models APX525, APX625, APX725
and APX825:
Flame failure after 1 try to restart.
•
•
104
Heating load at time of error was far below the minimum firing
rate of the boiler.
Defective system circulator or no flow in primary loop.
Defective boiler circulator, no flow or insufficient flow in boiler loop,
or defective flow switch.
Control system miswired so that the boiler operation is
permitted when no zones are calling.
105
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.
106
XIII. Repair Parts (continued)
Heat Exchanger Components
Part Number
Key
Description
No.
APX425
APX525
APX625
1A
Air Vent Valve
101586-01
1B
Supply/Return Water Temperature Sensor (2 per boiler)
101685-01
1C
High Limit Water Temperature Sensor
Replacement Rear Insulation Disc Kit (includes insulation,
disc, thermal link switch and instructions)
(Warning: Contains RCF)
Flue Exit Gasket Replacement Kit (includes gasket and
dielectric grease)
101653-01
1D
1E
1G Temperature and Pressure Gauge (not shown)
Safety Relief Valve (not shown)
1H Alternate Safety Relief Valve Kit (not shown, includes safety
relief valve and temperature and pressure gage
1J Boiler Drain Valve, 3/4 in. NPT (not shown)
APX725
APX825
104998-01
104501-01
104502-01
100282-01
103470-02
50 PSI: 103837-01
60 PSI: 81660375
80 PSI: 104200-01
100 PSI: 104201-01
806603061
Burner Components
Key
Description
No.
Part Number
APX425
APX525
APX625
APX725
1K
Replacement Burner Kit (includes burner, burner head seal
and hardware)
104988-01 104989-01
1L
Replacement Burner Door Kit (includes door, burner door
inner and outer seals, gaskets for sensor and ignitor,
insulation and thermostat; does not include igniter or flame
sensor)
104992-01
104993-01
1M
Burner Door Insulation (Warning: Contains RCF)
101728-01
103610-01
1N
Replacement Flame Sensor Kit (includes gasket and
hardware)
103339-01
103310-01
1O
Replacement Igniter Kit (includes gasket and hardware)
103005-01 103005-02
103308-01
1P
Replacement Gas/Air Duct Kit (includes duct gaskets and
hardware)
104994-01 104995-01
104996-01
1Q
Burner Gasket
102739-01
104986-01
1R
Burner Door Outer Seal
101730-01
104985-01
1S
Burner Door Thermostat with Manual Reset
104569-01
1T
Burner Door Hex Flange Nut, M6 x 1.0 mm (6 per boiler)
101724-01
104990-01
APX825
104991-01
107
XIII. Repair Parts (continued)
APX425 and APX525
Blower / Gas Train Components
Key
Description
No.
Part Number
APX425
APX525
APX625
APX725
APX825
2A
Replacement Blower Kit (includes blower, blower
outlet gasket and hardware)
104999-01 104999-02
104999-03
2B
Blower Outlet Gasket
101345-01 102614-01
103263-01
2C
Blower Inlet Assembly (includes gas orifice, injector
flange, inlet shroud (425 and 525 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 105004-02
2F
Gas Valve Flange Kit (includes one 90° gas valve
flange, o-ring, and hardware)
2G
Gas Valve Wire Harness (includes harness with
plug and M4 x 30 mm screw)
2H
Gas Line Rubber Grommet
3/4 in. NPT: 101638-01
1 in. NPT: 103252-01
2J
Gas Shutoff Valve
3/4 in. NPT: 101615-01
1 in. NPT: 816SOL0015
108
N/A
102971-01
Natural Gas: Natural Gas:
105001-01
105001-02
LP Gas:
105000-01
N/A
LP Gas:
105000-02
103223-01
N/A
Natural Gas: 105004-04
LP Gas: 105004-03
102972-03
Natural Gas: 103225-01
LP Gas: 103300-01
N/A
109
XIII. Repair Parts (continued)
APX625, APX725 and APX825
(APX825 shown)
XIII. Repair Parts (continued)
Condensate Trap and Related Components
Key
Description
No.
Part Number
APX425
APX525
APX625
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
104704-01
105006-01
3F
Limestone Chips, 2 lb. bag (not shown)
101873-01
3G
Air Pressure Switch
104426-01
3H
Air Pressure Switch Tubing, Silicone, 3/16 in. ID x 0.07
in. Wall Thickness
110
13.5 in.
7016041
22 in.
102770-01
APX725
24 in. 104658-01
APX825
104704-01
28 in.
103257-01
XIII. Repair Parts (continued)
Control Components
Key
No.
Description
Part Number
APX425
APX525
104472-01
104472-04
APX625
APX725
Natural Gas: 105008-02
LP Gas: 105008-01
4A
Replacement Sage2.1 Control (programmed)
4B
Replacement Display
(programmed, includes mounting hardware)
4C
Transformer
4D
Upper Front panel
102778-01
4E
Control Slide Out Tray
103336-01
APX825
104472-04
104779-01
102516-01
103193-01
111
112
XIII. Repair Parts (continued)
APX425 and APX525
XIII. Repair Parts (continued)
Sheet Metal, APX425 and APX525
Key
No.
Description
Part Number
APX425
APX525
5A
Replacement Left Side Panel Kit
(includes labels, access panels, grommets and header gaskets)
105017-01
105017-02
5B
Replacement Right Side Panel Kit
(includes labels, access panels and gaskets)
105018-01
105018-02
5C
Replacement Top Panel Kit (includes labels)
105019-01
105019-02
5D
Replacement Front Door Kit (includes labels)
105016-01
105016-02
5E
Replacement Rear Panel Kit (includes access panel and gaskets)
5F
High Voltage Terminal Bracket
102780-01
5G
Replacement Access Panel Kit, 5 in. x 8 in. (includes gasket)
105010-01
5H
Replacement Access Panel Kit, 5 in. x 16 in. (includes gasket)
5J
Access Panel Gasket, 5 in. x 8 in.
5K
Access Panel Gasket, 5 in. x 16 in.
5L
Replacement Handle Kit (includes gasket)
5M
Gas Train Bracket
5N
Nylon Glide Replacement Kit (includes 6 glides)
105014-01
5O
Replacement Door Latch Kit (includes rivets)
105012-01
5P
Replacement Stacking Bracket Kit (not shown, includes 4 brackets and hardware)
105022-01
5Q
CPVC/PVC Vent System Connector Replacement Kit
(includes gasket and flue temperature sensor cap)
4 in. x 4 in. 105021-01
5R
CPVC/PVC Vent System Connector Gasket
4 in. x 4 in. 102185-02
5S
Flue Temperature Sensor Replacement Kit (includes sensor and cap)
105013-01
5T
Flue Temperature Sensor Cap
105027-01
N/A
N/A
105011-01
102877-01
N/A
102613-01
105015-01
N/A
102611-01
113
114
XIII. Repair Parts (continued)
APX625, APX725 and APX825
XIII. Repair Parts (continued)
Sheet Metal, APX625, APX725 and APX825
Key
No.
Description
Part Number
APX625
APX725
APX825
5A
Replacement Left Side Panel Kit
(includes labels, access panels, grommets and header gaskets)
105017-03
105017-04
5B
Replacement Right Side Panel Kit
(includes labels, access panels and gaskets)
105018-03
105018-04
5C
Replacement Top Panel Kit (includes labels)
105019-03
105019-04
5D
Replacement Front Door Kit (includes labels)
5E
Replacement Rear Panel Kit (includes access panel and
gaskets)
105016-02
5F
High Voltage Terminal Bracket
102780-01
5G
Replacement Access Panel Kit, 5 in. x 8 in. (includes gasket)
105010-01
5H
Replacement Access Panel Kit, 5 in. x 16 in. (includes gasket)
N/A
5J
Access Panel Gasket, 5 in. x 8 in.
102877-01
5K
Access Panel Gasket 5 in. x 16 in.
N/A
5L
Replacement Handle Kit (includes gasket)
N/A
5M
Gas Train Bracket
103240-01
5N
Nylon Glide Replacement Kit (includes 6 glides)
105014-01
5O
Replacement Door Latch Kit (includes rivets)
105012-01
5P
Replacement Stacking Bracket Kit (not shown, includes 4
brackets and hardware)
105022-01
5Q
CPVC/PVC Vent System Connector Replacement Kit
(includes gasket and flue temperature sensor cap)
6 in. x 6 in. 105021-02
5R
CPVC/PVC Vent System Connector Gasket
6 in. x 6 in. 103248-01
5S
Flue Temperature Sensor Replacement Kit (includes sensor and
cap)
105013-01
5T
Flue Temperature Sensor Cap
105027-01
105020-01
105020-02
115
XIII. Repair Parts (continued)
Additional Components
Key
Description
No.
Part Number
APX425
APX525
APX625
APX725
6B
CSD-1 Kit (not shown, includes manual reset high
limit, immersion well, gas pressure switches, and
hardware)
Gas Pressure Switch Assembly
N/A
102670-01
6C
Low Gas Pressure Switch
N/A
102702-01
6D
High Gas Pressure Switch
N/A
102703-01
6E
N/A
102704-01
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)
6M
6N
6A
6F
6G
6H
6J
6K
116
104780-01
104927-01
104926-01
102946-01
101935-01
103104-01
4 in. 102193-02
6 in. 103267-01
Schedule 80 CPVC 90° Elbow (not shown)
4 in. 102192-02
6 in. 103268-01
Rodent Screen (not shown)
4 in. 102191-02
6 in. 102191-03
APX825
XIII. Repair Parts (continued)
Wiring Harnesses
Key
No.
Description
--10A
10B
10C
10D
10E
10F
Complete Wiring Harness (includes 10A, 10B, 10C & 10D)
Main (Low Voltage) Harness
High Voltage Harness
Blower Power Harness
Communication Harness
Igniter Harness
Wiring Harness, Thermal Link and Burner Door Thermostat
Part Number
APX425
APX525
APX625
102701-02
103009-02
103010-02
103012-01
103011-01
103486-01
104574-01
APX725
APX825
117
Appendix A - Figures
Figure
Number
Page
Number
Description
Section I - Product Description, Specifications & Dimensional Data
Figure 1A
6
Apex - Model APX425
Figure 1B
7
Apex - Model APX525
Figure 1C
8
Apex - Models APX625 and APX725
Figure 1D
9
Apex - Model APX825
Section III - Pre-Installation and Boiler Mounting
Figure 2
12
Clearances To Combustible and Non-combustible Material
Figure 3
14
Stacking Boiler Attachment Bracket Placement
Section IV - Venting
Figure 4
17
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 5A
18
Direct Vent - Sidewall Tee Terminations
Figure 5B
19
Direct Vent - Sidewall Elbow Terminations, Size 625 through 825 only
Figure 6A
19
Direct Vent - Optional Vent Sidewall Snorkel Termination
Figure 6B
19
Direct Vent - Optional Vent & Combustion Air Sidewall Snorkel Terminations
Figure 7
20
Direct Vent - Vertical Terminations
Figure 8
20
Direct Vent - Vertical Terminations w/ Sloped Roof
Figure 9
22
Field Installation of CPVC/PVC Two-Pipe Vent System Connector
Figure 10
23
Near-Boiler Vent/Combustion Air Piping
Figure 11
24
CPVC/PVC Expansion Loop and Offset
Figure 12
24
Wall Penetration Clearances for PVC Vent Pipe
Figure 13
25
Rodent Screen Installation
Figure 14
28
Vent System Field Modification to Install PVC to PP Adapter (M&G/DuraVent Shown)
Figure 15
29
Flexible Vent in Masonry Chimney with Separate Combustion Air Intake
Figure 16
30
Field Installation of Two-Pipe Vent System Adapter for Stainless Steel
Figure 17
34
Multiple Boiler Direct Vent Termination
Section V - Condensate Disposal
Figure 18
36
Condensate Trap and Drain Line
Section VI - Water Piping and Trim
Figure 19A
37
Factory Supplied Piping & Trim Installation - APX425 and APX525
Figure 19B
38
Factory Supplied Piping & Trim Installation - APX625 and APX725
Figure 19C
39
Factory Supplied Piping & Trim Installation - APX825
Figure 20
45
Near Boiler Piping - Heating Only
Figure 21
46
Near Boiler Piping - Heating Plus Indirect Water Heater
Figure 22A
47
Isolation of the Boiler From Oxygenated Water with A Plate Heat Exchanger
(IWH Piped as Part of Boiler Piping)
Figure 22B
48
Isolation of the Boiler From Oxygenated Water with A Plate Heat Exchanger
(IWH Piped Off System Header)
Figure 23A
49
Multiple Boiler Water Piping w/Domestic Hot Water Heater (Page 1 of 2)
Figure 23B
50
Multiple Boiler Water Piping w/Domestic Hot Water Heater (Page 2 of 2)
118
Appendix A - Figures (continued)
Figure
Number
Page
Number
Description
Section VII - Gas Piping
Figure 24
53
Recommended Gas Piping
Figure 25
54
Gas Inlet Pressure Tap and Pressure Switch Location
Section VIII - Electrical
Figure 26
57
Ladder Diagram
Figure 27
58 & 59
Figure 28A
60
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 28B
61
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 29
62
Multiple Boiler Wiring Diagram, Internal Sage2.1 Multiple Boiler Control Sequencer (Three Boilers
Shown, Typical Connections for up to Eight Boilers)
Figure 30A
63
Multiple Boiler Wiring Diagram w/Tekmar 265 Control
Figure 30B
64
Multiple Boiler Wiring Diagram w/Tekmar 264 Control
Figure 31
65
Recommended Direct Immersion Header Sensor Installation Detail
Figure 32
65
Alternate “Immersion” type Header Sensor Installation Detail
Figure 33
66
RJ45 Splitter Installation Detail
Wiring Connections Diagram
Section IX- System Start-Up
Figure 34
68
Operating Instructions
Figure 35
70
Burner Flame
Figure 36
70
Gas Valve Detail
Section X - Operation
Figure 37
81
Status Screens
Figure 38
82
Detail Screens
Figure 39
84
Adjust Mode Screens
Figure 40
93
Outdoor Reset Curve
Section XI - Service and Maintenance
Figure 41
98
Igniter Electrode Gap
Figure 42
99
Condensate Overflow Switch Orientation
Section XII - Troubleshooting
Figure 43
101
Help Menu
Section XIII - Repair Parts
N/A
Pages 106 through 117
119
Appendix B - Tables
Table
Number
Page
Number
Description
Section I - Product Description, Specifications & Dimensional Data
Table 1A
5
Specifications
Table 1B
5
Dimensions (See Figures 1A, 1B, 1C and 1D)
Table 2
10
Ratings
Section III - Pre-Installation and Boiler Mounting
Table 3
13
Apex Boiler Model Stacking Combinations
Section IV - Venting
Table 4
16
Vent/Combustion Air System Options
Table 5
16
Vent/Combustion Air Pipe Length – Two-Pipe Direct Vent System Options
CPVC/PVC
Polypropylene (PP) or Polypropylene (PP)/PVC
Stainless Steel/PVC or Galvanized Steel)
Table 6A
17
Vent System and Combustion Air System Components Equivalent Length vs. Component Nominal
Diameter
Table 6B
18
Vent Combustion Air Equivalent Length Calculation Work sheet
Table 7A
21
CPVC/PVC Vent & Air Intake Components Included With Boiler
Table 7B
21
CPVC/PVC Vent & Air Intake Components (Installer Provided) required for Optional Horizontal
(Snorkel) Termination
Table 7C
22
CPVC/PVC Vent & Air Intake Components (Installer Provided) required for Optional Vertical (Roof)
Termination
Table 8
24
Expansion Loop Lengths
Table 9
26
Listed Polypropylene Vent System Manufacturers
Table 10A
27
Listed Polypropylene Pipe, Fittings and Terminations - M&G/DuraVent
Table 10B
27
Listed Polypropylene Pipe, Fittings and Terminations - Centrotherm Eco
Table 11A
30
Thermal Solutions Vent System Components (Stainless Steel)
Table 11B
30
Alternate Vent Systems and Vent Components (Stainless Steel)
Section VI - Water Piping and Trim
Table 11C
35
Maximum Condensate Flow
Table 12
41
Flow Range Requirement Through Boiler
Table 13A
42
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 13B
42
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 14
43
Fitting & Valve Equivalent Length
Table 15
47
Multiple Boiler Water Manifold Sizing
Section VII - Gas Piping
Table 16A
51
Maximum Capacity of Schedule 40 Black Pipe in CFH* (Natural Gas) For Gas Pressures of 13.8
in. w.c. or Less
Table 16B
52
Maximum Capacity of Schedule 40 Black Pipe in CFH* (LP Gas) For Gas Pressures of 0.5 psig or
Less
Table 17
52
Equivalent Length of Standard Pipe Fittings & Valves
Table 18
53
Specific Gravity Correction Factors
Table 19
53
Min./Max. Pressure Ratings
120
Appendix B - Tables (continued)
Table
Number
Page
Number
Description
Section VIII - Electrical
Table 20
56
Boiler Current Draw
Section IX - System Start-Up
Table 21
69
Typical Combustion Settings, Natural Gas
Table 22
70
Typical Combustion Settings, LP Gas
Table 23
72
Approximate Number of Clockwise Throttle Screw Turns for LP Conversion
Table 24A
73
Approximate Throttle Screw Adjustment Values from Fully Closed Position, Natural Gas
Table 24B
73
Approximate Throttle Screw Adjustment Values from Fully Closed Position, LP Gas
Section X - Operation
Table 25
76
Order of Priority
Table 26
77
Frost Protection
Table 27
79
Boiler Sequence of Operation
Table 28
86
Parameters Changed Using the Boiler Type Parameter Selections
Section XIII - Repair Parts
N/A
Pages 107 through 117
121
122
123
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.
124
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