AHRI APEX Installation, Operating And Service Instructions

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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 quali ed 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.

Indicates a potentially hazardous situation which, if not avoided, may result in moderate or minor injury or property damage.

CAUTION

NOTICE

WARNING

Indicates a potentially hazardous situation which, if not avoided, could result in death, serious injury or substantial property damage.

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 ammable 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 re department.

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 satised:

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 oor 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 oor 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 identication 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 nal 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 ue gases, but identies “special venting systems”, the following shall be satised:

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.

TABLE OF CONTENTS

I. Product Description, Specications 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

I. Product Description, Specications and Dimensional Data

Apex Series boilers are condensing high efciency gas-red

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 ue gas product

corrosion. These boilers are not designed for use in gravity hot water space heating systems or systems containing

signicant amount of dissolved oxygen (swimming pool

water heating, direct domestic hot water heating, etc.).

Table 1A: Specications

Specication

Altitude (ft. above sea level) 0-4500 0-4500 0-2000 0-2000 0-4500

Fuel

Max. Allowable Water Temperature (°F) 210 210 210 210 210

Max. Allowable Working Pressure (psi) 160 160 160 160 160

Factory Supplied Safety Relief Valve (psi)

Boiler Water Volume (gal.) 3.4 4.2 5.5 5.5 5.0

Heat Transfer Area (sq. ft.) 41.8 50.8 76.2 76.2 65.3

Approx. Shipping Weight (lb.) 304 350 455 455 430

APX425 APX525 APX625 APX725 APX825

Shipped for Natural Gas, Field

Converted for LP Gas

50 50 60 60 60

Boiler Model

Shipped for Natural Gas or Shipped for LP Gas

(no Field Conversion)

* 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)

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

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)

3/4” 3/4” 1” 1” 1”

Factory Provided Socket End Compression Pipe Joining Clamp for 3/4” Schedule 40

PVC Pipe

4 x 4 6 x 6 6 x 6 6 x 6

44-7/8 (1140)

22-1/8

(562)

(737)

39-11/16

(1008) 29-3/8

(752)

Boiler Model

50-1/4 (1276)

N/A N/A

(610)

38-7/8

(987)

31-5/8

(803)

50-1/4 (1276)

(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)

I. Product Description, Specications and Dimensional Data (continued)

Figure 1A: Apex - Model APX425

I. Product Description, Specications and Dimensional Data (continued)

Figure 1B: Apex - Model APX525

I. Product Description, Specications and Dimensional Data (continued)

Figure 1C: Apex - Models APX625 and APX725

I. Product Description, Specications and Dimensional Data (continued)

Figure 1D: Apex - Model APX825

I. Product Description, Specications and Dimensional Data (continued)

Table 2: Ratings

Apex Series Gas-Fired Boilers

Model

Number

APX425 80 399 375 326 94.1 94.5

APX525 100 500 475 413 95.0 95.0

APX625 125 625 594 516 95.0 96.0

APX725 145 725 689 599 95.0 95.0

APX825 160 800 760 661 95.0 93.0

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.

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.

Input (MBH)

Min. Max.

Gross Output

(MBH)

Net Ratings Water

(MBH)

Thermal

Efciency (%)

Combustion

Efciency (%)

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.

D. Remove boiler from cardboard positioning sleeve

on shipping skid.

E. Move boiler to its permanent location.

III. Pre-Installation and Boiler Mounting

WARNING

Explosion Hazard. Asphyxiation Hazard. Electrical Shock Hazard. Installation of this boiler should be undertaken only by trained

and skilled personnel from a qualied 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 ue 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.

1. Access to boiler front is provided through a door or removable front access panel.

2. Access is provided to the condensate trap located underneath the heat exchanger.

3. Access is provided to thermal link located at boiler rear.

D. Protect gas ignition system components

from water (dripping, spraying, rain, etc.) during boiler operation and service (circulator replacement, condensate trap, control replacement, etc.).

E. Provide combustion and ventilation air in

accordance with applicable provisions of local building codes, or: USA - National Fuel Gas Code, ANSI Z223.1/NFPA 54, Air for Combustion and Ventilation;

Canada - Natural Gas and Propane Installation Code,

CAN/CSA-B149.1, Venting Systems and Air Supply for Appliances.

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, chlorouorocarbons,

paint removers, cleaning solvents and detergents.

Avoid areas containing saw dust, loose insulation bers,

dry wall dust etc.

NOTICE

Avoid operating this boiler in an environment

where sawdust, loose insulation bers, 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.

B. Boileriscertiedfor installation on combustible

ooring. Do not install boiler on carpeting.

C. Provide clearance between boiler jacket and

combustible material in accordance with local re

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:

G. General.

1. Apex boilers are intended for installations in an

area with a oor 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.

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 oor is not level or where water may be encountered on the oor

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)

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

Available Optional

Two-Pipe Stainless Steel Vent and

Galvanized Steel or PVC Combustion

Air Intake

* Do not enclose PVC venting - use CPVC vent pipe in enclosed spaces, or to penetrate through

combustible or non-combustible walls.

Listed Direct Vent System

* 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.

Vent Pipe

Material

* CPVC/PVC

Pipe Rigid

Polypropylene

Vent (or,

Flexible

Polypropylene

Liner for

Vertical

Venting only)

Stainless

Steel

Vent Pipe

Direction

Vertical or Horizontal

Enclosure

Unenclosed

at all Sides

Vent Pipe

Nominal

Diameter

4 in. (100 mm)

6 in.( 150 mm)

4 in. (100 mm)

or (110 mm)

6 in. (150 mm)

or (160 mm)

4 in. (100 mm)

6 in.( 150 mm)

Minimum Clearance to Combustible

Material

1 in. (25 mm)

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 benets of greater operational efciency, oor 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 Model

APX425

APX525 APX425 or APX525 APX625 APX425, APX525 or APX625 APX725 APX425, APX525, APX625 or APX725

APX825

2. To eld assemble individual Apex boilers into a stackable conguration, use the steps below:

a. Position the bottom boiler rst. Refer to Sections

b. Each Apex boiler is factory packaged with

c. Apex boiler left and right side panels have a

d. Position the upper boiler on top of the bottom

Top Boiler Model

APX425

APX425, APX525, APX625, APX725 or APX825

II “Unpacking Boiler” and III “Pre-Installation & Boiler Mounting” of the manual for details.

Always position higher input boiler model as bottom boiler.

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”.

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 specic

pattern to compensate for Apex boiler model variable depth.

boiler and align boiler front doors and sides ush

with each other.

• Place rst 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 veried, 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 specics of individual boiler

vent termination. Follow instructions in Section V “Condensate Disposal” for each individual

boiler ue 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 sufcient ow capacity

to handle combined condensate volume of stackable combination.

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 ow) 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

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, chlorouorocarbons (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 specied vent and combustion air pipe diameters. Do not reduce specied diameters of vent and

combustion air piping.

Do not interchange vent systems or materials unless otherwise specied. Do not apply thermal insulation to vent pipe or ttings.

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 re ofcials 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 ue

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 specic

details.

ii. Two-Pipe Polypropylene Vent/Combustion

Air System - Separate rigid or exible

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

specic 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 specic 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 ttings). Table 6A lists equivalent lengths for ttings.

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 re resistance rating at least equal to the rating of adjoining oor or ceiling.

Note: For one or two family dwellings, re

resistance rating requirement may not need to be met, but is recommended.

IV. Venting A. General Guidelines (continued)

Table 4: Vent/Combustion Air System Options

Approved Direct

Vent System

Factory Standard

Two-Pipe,

CPVC/PVC Vent and

PVC Air Intake

Available Optional

Two-Pipe, Rigid

Polypropylene Vent (or

Flexible Polypropylene

Liner for Vertical

venting only) and Rigid

Polypropylene or PVC

Pipe Air Intake

Available Optional

Two-Pipe,

Stainless Steel Vent and

PVC/Galvanized Steel

Air Intake

Vent

Material

CPVC/PVC

Rigid

Polypropylene

(or Flexible

Polypropylene

Liner for vertical

Venting only)

Stainless Steel

Orientation Termination Description Figures

Standard

(through sidewall)

Horizontal

Optional

Snorkel

(through sidewall)

Optional

Vertical

Horizontal

Optional

Vertical

Horizontal

Vertical

(through roof)

Standard

(through sidewall)

Optional Snorkel

(through sidewall)

Vertical

(through roof or chimney/chase)

Standard

(through sidewall)

Optional Snorkel

(through sidewall)

Vertical (through

roof)

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.

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.

4, 5A, 5B

9 through 13

4, 6A, 6B

9 through 13

7 through 11

4, 5A, 5B

9, 12, 14

4, 6A, 6B

9, 12, 14

7 through 9

14, 15

4, 5A, 5B

9, 12, 16

4, 6A, 6B

9, 12, 16

7 through 9

Component

Table

10A, 10B

11A, 11B D.

Part

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)

Combustion Air Vent

Boiler

Model

APX425

APX525

APX625

APX725

APX825

Nominal

Pipe

Diameter

4 in.

(100 mm or 110 mm)

6 in.

(150 mm or 160 mm)

Minimum

Equivalent

Length

2.5 ft.

(760 mm)

2.5 ft.

(760 mm)

Maximum

Equivalent

Length

100 ft.

(30.5 m)

200 ft.

(61.0 m)

Nominal

Pipe

Diameter

4 in.

(100 mm or 110 mm)

6 in.

(150 mm or 160 mm)

Minimum

Equivalent

Length

2.5 ft.

(760 mm)

2.5 ft.

(760 mm)

Maximum

Equivalent

Length

100 ft.

(30.5 m)

200 ft.

(61.0 m)

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 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

Equivalent Length for Vent or Combustion Air System Component

vs. Component Nominal Diameter

prévenir le échissement. Les méthodes et les intervalles de support doivent être spéciés.

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 specically required by these

instructions (refer to Figure 4).

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)

Subtotal,

Equivalent

Length (A)

Nominal Diameter

4 in.

(100 mm or 110 mm)

6 in.

(150 mm or 160 mm)

Quantity

(Pc)

Equivalent Length,

per Pc

1 13 ft. (4.0 m) 13 ft. (4.0 m)

1 22 ft. (6.7 m) 22 ft. (6.7 m)

Nominal Diameter

4 in.

(100 mm or 110 mm)

6 in.

(150 mm or 160 mm)

Quantity

(Pc)

Equivalent

Length, per Pc

13 ft. (4.0 m)

22 ft. (6.7 m)

45° Elbow(s) (Installer Supplied) 90° Elbow(s) (Installer Supplied)

Nominal Diameter

4 in.

(100 mm or 110 mm)

6 in.

(150 mm or 160 mm)

Quantity

(Pc)

Equivalent

Length, per Pc

4.5 ft. (1.4 m)

7.5 ft. (2.3 m)

Subtotal,

Equivalent

Length (B)

Nominal Diameter

4 in.

(100 mm or 110 mm)

6 in.

(150 mm or 160 mm)

Quantity

(Pc)

Equivalent Length,

per Pc

13 ft. (4.0 m)

22 ft. (6.7 m)

Straight Pipe, (Installer Supplied) 45° Elbow(s) (Installer Supplied)

Nominal Diameter

4 in.

(100 mm or 110 mm)

6 in.

(150 mm or 160 mm)

Quantity

Length,

ft or m

Equivalent

Length,

ft/ft or m/m

Subtotal,

Equivalent

Length (C)

Nominal Diameter

4 in.

(100 mm or 110 mm)

6 in.

(150 mm or 160 mm)

Quantity

Length,

ft or m

Equivalent Length,

ft/ft or m/m

4.5 ft. (1.4 m)

7.5 ft. (2.3 m)

* Total Equivalent Length (A+B+C) = 2.5 Ft. (760 mm) Straight Pipe, (CPVC Supplied with Boiler)

* 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 exible polypropylene liner is 20% greater than for rigid pipe. Multiply measured exible polypropylene liner length by 1.2 to obtain equivalent length.

Example Measure length of exible polypropylene liner = 35 ft. Equivalent length of exible polypropylene liner = 35 ft. x 1.2 = 42 ft.

4. Maximum equivalent length of exible polypropylene liner

is 48 ft. (14.6 m).

5. All elbows referenced are short radius.

Nominal Diameter

4 in.

(100 mm or 110 mm)

6 in.

(150 mm or 160 mm)

Nominal Diameter

4 in.

(100 mm or 110 mm)

6 in.

(150 mm or 160 mm)

Quantity

Length,

ft or m

2.5 ft.

(0.76 m)

2.5 ft.

(0.76 m)

Equivalent Length,

ft/ft or m/m

1 2.5 ft.

Straight Pipe, (Installer Supplied)

Quantity

Length,

Equivalent Length,

ft/ft

* Total Equivalent Length (A+B+C+D+E) =

Subtotal,

Equivalent

Length (D)

Subtotal,

Equivalent

Length (A)

Subtotal,

Equivalent

Length (B)

Subtotal,

Equivalent

Length (E)

2.5 ft.

(0.76 m)

Subtotal,

Equivalent

Length (C)

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.

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, soft, or roof

overhang 12 in. (300 mm) or less wide. If eave,

soft, or roof overhang is wider than 12 in. (300

mm), increase vertical clearance to 5 ft. (1.5 m)

to avoid ue 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 ue gas

may condense, and possibly freeze, on objects around the terminal including on the structure

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

Asphyxiation Hazard. Failure to follow these instructions could cause products of combustion to enter the building, resulting in severe property damage, personal injury,

Figure 7: Direct Vent - Vertical Terminations

itself. If these objects are subject to damage by

ue 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

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.

WARNING

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.

Figure 8: Direct Vent - Vertical Terminations

with Sloped Roof

IV. Venting B. CPVC/PVC Venting (continued)

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. 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

2. Field Installation of CPVC/PVC Two-Pipe Vent System Connector

Refer to Figure 9 and following steps:

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.

c. Attach ue 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 ash Red and display Limit String

Fault (see Section XII “Troubleshooting” for details).

NOTICE

Flue temperature sensor harness must be

connected to ue temperature sensor for the

boiler to start-up and operate properly. The installation is not complete unless the harness and the sensor are interconnected.

Table 7A: CPVC/PVC Vent & Air Intake Components Included With Boiler

Quantity

Vent & Air Intake Components

Schedule 40 PVC Tee 102190-02 (Qty. 2) N/A Schedule 40 PVC 90° Elbow N/A 103313-01 (Qty. 2) Stainless Steel Rodent Screen 102191-02 (Qty. 2) 102191-03 (Qty. 2) 30 in. Schedule 40 CPVC Pipe 102193-02 103267-01 Schedule 80 CPVC 90° Elbow 102192-02 103268-01

4 oz. Bottle of Transition Cement 102195-01 4 oz. Bottle of Primer 102194-01 CPVC/PVC Connector 4 in. x 4 in. 102183-03 6 in. x 6 in. 103270-01 CPVC/PVC Connector Gasket 4 in. x 4 in. 102185-02 6 in. x 6 in. 103248-01

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

Table 7B: CPVC/PVC Vent & Air Intake Components (Installer Provided) required for Optional Horizontal

(Snorkel) Termination

Quantity

Vent Components

Schedule 40 PVC Pipe x up to 7 ft. (2.1 m) max. vertical run 2 2 Schedule 40 PVC 90° Elbow 4 4 Schedule 40 PVC Pipe x 6 in. (150 mm) min. horizontal run 2 N/A Schedule 40 PVC Pipe x 9 in. (230 mm)min. horizontal run N/A 2

APX425 & APX525

Horizontal (Snorkel)

Termination, 4 in.

APX625, APX725 & APX825

Horizontal (Snorkel)

Termination, 6 in.

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 1 1 Schedule 40 PVC 90° Elbow 2 2

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

Vertical (Roof) Termination, 4 in.

1 N/A

N/A 1

APX625, APX725 & APX825

Vertical (Roof) Termination, 6 in.

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:

Apply supplied dielectric grease (grease pouch

attached to two-pipe vent connector) to gasket

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.

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 ue 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 ue gas leaks.

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

conguration 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 rst 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

ttings 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.

IV. Venting B. CPVC/PVC Venting (continued)

Table 8: Expansion Loop Lengths

Nominal

Pipe

Dia. (In.)

Length of

Straight Run

ft. m 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

Loop Length

“L”

Figure 11: CPVC/PVC Expansion Loop and Offset

i. Vent Piping

Running PVC vent pipe inside Enclosures

and through Walls:

• PVC vent pipe must be installed in such

way as to permit adequate air circulation around the outside of the pipe to prevent internal wall temperature rising above

ANSI Z21.13 standard specied 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 non-

combustible wall.

• Insert thimble into cut opening from outside. Secure thimble outside ange 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 non-

combustible 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 conguration 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 conguration

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 conguration.

• 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 conguration.

• Brace exterior piping if required.

6. Vertical Roof Termination

a. Standard Two-Pipe Termination

See Figures 7 and 8.

i. Vent Piping

• Install re stops where vent passes through oors, ceilings or framed walls. The re 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

- 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 ashing and storm collar, which are not

supplied with boiler, to prevent moisture from entering the structure.

- Install storm collar on vent pipe

immediately above ashing. Apply

Dow Corning Silastic 732 RTV

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 conguration.

• 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 ashing and storm

collar to prevent moisture from entering the structure.

- Use appropriately designed

vent ashing when passing through roofs. Follow ashing 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

ashing. 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 conguration.

• Brace exterior piping if required.

C. Polypropylene Venting

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 conict 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.

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

M&G/

DuraVent

Centrotherm

Eco Systems

WARNING

NOTICE

PolyPro Single Wall Rigid Vent PolyPro Flex Flexible Vent (APX425 and

APX525) InnoFlue SW Rigid Vent Flex Flexible Vent (APX425 and

APX525)

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 specic M&G Duravent

components.

c. See Table 10B for specic Centrotherm Eco

Systems components.

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.

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 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.

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:

• Make sure that gasket is in position and un-

damaged in the female end of the pipe.

• Make sure that both the male and female

pipes are free of damage prior to assembly.

• Only cut vent pipe as permitted by the

vent manufacturer in accordance with their instructions. When pipe is cut, cut end

must be square and carefully de-burred prior

to assembly.

• Use locking band clamps at all vent pipe

joints.

a. Plan venting system to avoid possible contact

with plumbing or electrical wires. Start at vent connector at boiler and work towards vent termination.

Table 10A: Listed Polypropylene Pipe, Fittings and Terminations - M&G/DuraVent

Boiler Model

APX425

APX525 APX625

APX825

Male Boiler Adapter,

PVC to PP

4PPS-04PVCM-4PPF

6PPS-06PVCM-6PPF

Rigid Pipe

Nominal Dia.

4 in.

(100 mm)

6 in.

(150 mm)

M&G / DuraVent Part Numbers/Sizes

Flex Pipe

Nominal Dia.

4 in.

(100 mm)

N/A 6PPS-LBC 6PPS-E90B N/AAPX725

Pipe Joint

Locking Band

43PPS-LB 43PPS-TB 4PPS-FK

Side Wall

Termination Tee

Table 10B: Listed Polypropylene Pipe, Fittings and Terminations - Centrotherm Eco

Boiler Model

APX425

APX525

APX625

APX825

Male Boiler Adapter,

PVC to PP

ISAA0404

ISSAL0404

ISAA0606

ISSAL0606

Rigid Pipe

Nominal Dia.

4 in.

(110 mm)

6 in.

(160 mm)

Centrotherm Eco Part Numbers/Sizes

Flex Pipe

Nominal Dia.

4 in.

(110 mm)

N/A IANS06 ISTT0620 N/AAPX725

Pipe Joint

Locking Band

IANS04 ISTT0420

Side Wall

Termination Tee

Chimney Kit for

Venting Only

Chimney Kit for

Venting Only

IFCK0425

and

IFCK0435

IV. Venting C. Polypropylene Venting (continued)

Figure 14: Vent System Field Modication 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

ue type, is considered UNUSED when none of the ues is being used for any appliance venting. Where one of the multiple ues is being used for an appliance venting, the exible

vent installation is not permitted through any of

adjacent ues.

NOTICE

Pressure drop for exible polypropylene liner is 20% greater than from rigid pipe. Multiply measured exible polypropylene liner length by

1.2 to obtain equivalent length. Maximum equivalent length of exible

polypropylene liner is 48 ft. (14.6 m).

a. Models APX425 and APX525 are listed for

vertical venting by installing exible 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 exible pipe if

it has been stored at lower ambient temperature without allowing the pipe to warm up to a higher

temperature rst.

WARNING

Asphyxiation Hazard. Bending or attempting

to install exible 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 ue gas leaks.

Do not install exible 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 exible 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

ow back towards the boiler.

f. When exible 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 exible polypropylene pipe (liner)

manufacturer specic installation instructions

regarding application/listing, permits, minimum clearances to combustibles, installation details (proper joint assembly, pipe support and routing,

gasket and tting 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 conict between exible

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 conict 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 ttings 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.

IV. Venting D. Stainless Steel Venting (continued)

Table 11A: Thermal Solutions Vent System Components (Stainless Steel, 4 in. only)

Part

Vent System

Component

SS Vent Kit 102501-02

Numbers

APX425 and

APX525

4 In. Vent

Equivalent

Length of Pipe

Horizontal Vent Terminal (Included in Kit)

PVC to SS Vent Adapter (Included In Kit)

Vertical Vent Terminal 102680-02 Pipe x 1 ft. (0.3 m) 100176-01 1 ft. (0.3 m) Pipe x 3 ft. (0.9 m) 100177-01 3 ft. (0.9 m) Pipe x 5 ft. (1.5 m) 100178-01 5 ft. (1.5 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 100182-01 2 ft. (0.6 m) Vertical Drain Tee 100183-01 7.5 ft. (2.3 m) Single Wall Thimble 100184-01 N/A

8116313

N/A

102220-01

Equal to

Installed Length

1.06 to 1.64 ft.

(0.3 m to 0.5 m)

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.

Figure 16: Field Installation of Two-Pipe Vent

System Adapter for Stainless Steel

2. Field Installation of CPVC/PVC Two-Pipe Vent System Connector and PVC to Stainless Steel 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 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

Apply a coating of supplied red RTV

only:

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 FasNseal

Z-Flex

NOTE: See vent system manufacturer’s literature for other part numbers that are required such as straight pipe, elbows, restops

and vent supports.

Vent

System

SVE Series III

(“Z-Vent III”)

Nominal Dia.

4 in.

(100 mm)

6 in.

(150 mm)

4 in.

(100 mm)

6 in.

(150 mm)

PVC to SS

Adapter

810005231 FSWT4 Tee: FSTT4 FSBS4

810005545 FSWT6 Tee: FSTT6 FSBS6

2SVSTTA04.5 2SVSWTF04 Tee: 2SVSTTX04 2SVSTPX04

2SVSTTA06.5 2SVSWTF06 Tee: 2SVSTTX06 2SVSTPX06

Wall Thimbles

Horizontal

Termination

Vertical

Termination

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 t 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.

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.

5. Vertical Vent Termination

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.

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 maxi mum speed. Do not operate a summer exhaust fan. Close

replace dampers.

4. Place in operation the appliance being inspected. Follow the Lighting (or Operating) Instructions. Adjust thermo stat so appliance will operate continuously.

5. Test for spillage at the draft hood relief opening after

5 minutes of main burner operation. Use the ame

of a match or candle, or smoke from a cigarette, cigar or pipe.

6. After it has been determined that each appliance remain ing connected to the common venting system properly vents when tested as outlined above, return

doors, win dows, exhaust fans, replace dampers and

any other gas burning appliance to their previous conditions of use.

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.

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

deciencies 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

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 amme 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 modiée, le système devrait être modié

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.

IV. Venting F. Multiple Boiler Installation Venting (continued)

Figure 17: Multiple Boiler Direct Vent Termination

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 ue gases in the boiler. The trap has factory installed overow 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 overow 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 ttings 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 overow from the pump would

result in property damage, select a pump with an

overow 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 overow.

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 lled 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 ll

the trap, inject water in the amount of 1 cup (240ml)

through condensate trap connection. Do not overll

the trap.

6. Install tee for condensate overow and vent as

shown in Figure 18.

WARNING

Asphyxiation Hazard. Failure to ll the

condensate trap with water prior to boiler start-

up could cause ue 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 ow shown in

Table 11C “Maximum Condensate Flow”.

Table 11C: Maximum Condensate Flow

Boiler Model

APX425 4.5

APX525 5.6

APX625 7.0

APX725 8.1

APX825 9.0

*Assumes 100% of water in fuel condenses.

*Maximum Condensate Flow,

GPH

WARNING

Asphyxiation Hazard. Failure to install the condensate drain in accordance with the above

instructions could cause ue gas to enter the

building, resulting in personal injury or death.

NOTICE

Boiler condensate is corrosive. Route condensate drain line in a manner such that any condensate leakage will not cause property damage.

Some jurisdictions may require that

condensate be neutralized prior to disposal.

Use materials approved by the authority having jurisdiction.

V. Condensate Disposal (continued)

Figure 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.

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 ll 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 ow switch with two boiler-specic 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 103259-02

Miscellaneous

Parts Carton

102942-05

104520-01

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.

Figure 19A: Factory Supplied Piping and Trim Installation - APX425 and APX525

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 ow 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 ow switch and paddles from packaging

carton. Also see/follow Taco Instruction Sheet

for Flow Switch Kit (supplied with the ow switch) for specic details.

l. Select the paddle stamped “1” for the APX425

and APX525.

m. Attach paddle to ow switch stem using supplied

machine screw.

n. Apply pipe dope to the switch-threaded brass-

bushing 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 ow direction for the best ow sensitivity. Do not tighten the

switch by grasping the switch enclosure. Use the

wrenching ats on the bushing only. The turning

radius required for the switch mounting is 3 in. (80 mm).

o. For ow 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 ow switch kit. Remove ow switch

and paddles from packaging carton. See Taco Instruction Sheet for Flow Switch Kit (supplied

with ow switch) for specic details.

f. For APX625, select paddle stamped “3”.

g. For APX725, select paddle stamped “1”.

h. Attach paddle to ow switch stem using supplied

machine screw.

i. Apply pipe dope to ow switch at threaded brass-

bushing 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 ow direction for best ow sensitivity. Do

not tighten switch by grasping switch enclosure.

Use wrenching ats on bushing only. The

turning radius required for switch mounting is 3 in. (80 mm).

j. For ow 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

VI. Water Piping and Trim A. Factory Supplied Piping and Trim (continued)

525

825

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 ow 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.

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 ow switch and paddles from packaging

carton. Also see/follow Taco Instruction Sheet

for Flow Switch Kit (supplied with ow switch) for specic details.

l. Select paddle stamped “1” for APX825.

m. Attach paddle to ow switch stem using supplied

machine screw.

n. Apply pipe dope to the switch-threaded brass-

bushing 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

Table 12: Flow Range Requirement Through Boiler

ΔT = 35°F ΔT = 30°F ΔT = 25°F ΔT = 20°F

Boiler

Model

APX425 1-1/2 1-1/2 21.5 6.1 25.1 7.9 30.2 10.8 37.7 15.9 APX525 1-1/2 1-1/2 27.1 6.9 31.7 8.9 38.0 12.1 47.5 17.6 APX625 2 2 33.9 4.7 39.6 6.1 47.5 8.4 59.4 12.4 APX725 2 2 39.4 6.0 45.9 7.9 55.1 10.9 68.9 16.1 APX825 2 2 43.4 12.1 50.7 15.5 60.8 20.9 76.0 30.0

Notes: Required Flow = Output*1000/(500*ΔT), where ow rate is in GPM, output is in MBH, and ΔT is in °F

Supply

Connection

(in.)

Return

Connection

(in.)

Minimum

Required

Flow (GPM)

Boiler Head

Loss (ft.)

Required

Flow

(GPM)

Boiler

Head Loss

(ft.)

Required

Flow

(GPM)

Boiler

Head Loss

(ft.)

Maximum

Required

Flow

(GPM)

Boiler

Head

Loss (ft.)

Outputs for specic 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 uid density and may require larger circulators.

Boiler Head Loss

Head

Loss

(ft.)

425

625/725

0 10 20 30 40 50 60 70 80

Water Flow Rate (GPM)

VI. Water Piping and Trim B. Piping System To Be Employed (continued).

perpendicular to the ow direction for the best ow sensitivity. Do not tighten the switch

by grasping the switch enclosure. Use the

wrenching ats on the bushing only. The turning

radius required for the switch mounting is 3 in. (80 mm).

o. For ow 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 ow through the boiler

remain within the limits shown in Table 12 any time the

boiler is ring.

NOTICE

Failure to maintain the ow through boiler within specied 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speciedowrangethroughboiler anytimetheboilerisring.

a. The ow rate through the isolated near-boiler

loop is maintained by installer supplied boiler circulator. See Tables 13A and 13B for recommended circulators.

b. The ow rate through the isolated near-boiler

loop is completely independent of the ow rate

through the heating system loop(s).

c. The ow 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 ow through boiler within

limits shown in Table 12.

Where it is not possible to install a separate boiler loop, the system circulator must be

sized to ensure that the ow through boiler stays within the dened parameters to prevent overheating when the boiler is red at it’s full rated input. Install a ow meter to measure the ow, or re the boiler at full rate and ensure the

boiler ΔT 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 ow rate through system must be the same

as through boiler and fall within limits specied

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 ow

at total calculated pressure drop.

c. It is often very difcult 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 ttings in the system. If system is zoned, the system ow rate

may drop well below recommended minimum

ow 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.

NOTICE

Model

Circulator

Model

Circulator

UPS43-100F,

Spd. 3

UPS40-80/4,

Spd. 3

UPS40-240/2,

Piping

Boiler &

Head Loss

Flow

(GPM)

Model

Circulator

Piping

Boiler &

Head Loss

Flow

(GPM)

Model

Circulator

Piping

Boiler &

Head Loss

(ft.)

Piping

Boiler &

Head Loss

Flow

(GPM)

Model

Circulator

Piping

Boiler &

Head Loss

Flow

(GPM)

Model

Circulator

Piping

Boiler &

Head Loss

(ft.)

37.7 16.9

UPS43-100F,

Spd. 2

47.5 19.1 UP43-110F

UPS43-100F,

38.0 13.1

UPS26-150F,

Spd. 3

Spd. 2

59.4 14.7

UPS43-100F,

47.5 9.9

UPS43-100F,

Spd. 3

Spd. 2

68.9 19.1 UP43-110F

Spd. 3

UPS40-80/4,

55.1 12.9

60.8 21.9 UP43-110F 76.0 31.6

Spd. 3

UPS40-80/4,

UPS43-100F,

Flow

(GPM)

Model

Circulator

Piping

Boiler &

Head Loss

Flow

(GPM)

(in.)

Pipe Size

(in.)

& Return

Connection

Boiler

Model

(ft.)

APX425 1½ 2 21.5 6.4 0014 25.1 8.4 0013 30.2 11.5 2400-20 37.7 16.9 2400-45

ΔT=35°F ΔT=30°F ΔT=25°F ΔT=20°F

Near Boiler

Supply

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]

39.6 7.2 2400-40 47.5 9.9 2400-60 59.4 14.7 2400-70

0012 or

APX525 1½ 2 27.1 7.4 0013 31.7 9.6 2400-20 38.0 13.1 2400-30 47.5 19.1 2400-50

APX625 2 2 33.9 5.5

2400-20

APX725 2 2 39.4 7.1 2400-40 45.9 9.4 2400-60 55.1 12.9 2400-65 68.9 19.1 2400-70

APX825 2 2½ 43.4 12.6 2400-45 50.7 16.3 2400-50 60.8 21.9 1915 76.0 31.6 1935

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]

Flow

Circulator

ΔT=35°F ΔT=30°F ΔT=25°F ΔT=20°F

Piping

Boiler &

Flow

Near

Boiler

Supply

& Return

Boiler

(GPM)

Model

Head Loss

(GPM)

Pipe Size

Connection

Model

(in.)

(ft.)

UPS43-44FC,

APX425 1½ 2 21.5 6.4 UP26-64F 25.1 8.4 UP26-99F 30.2 11.5

31.7 9.6

Spd. 3 or

UP26-99F

APX525 1½ 2 27.1 7.4

39.6 7.2

45.9 9.4

Spd. 3

Spd. 2

UPS43-100F,

UPS43-44FC,

APX625 2 2 33.9 5.5

APX725 2 2 39.4 7.1

50.7 16.3

Spd. 3

UPS43-100F,

APX825 2 2½ 43.4 12.6

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 oor. 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.

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 ll valve may be used. However, if automatic rell is employed, a water

meter must be added to evaluate the makeup water

volume taken after initial ll and eliminate any

water leakage as early as possible.

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 ow 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 ow switch is factory provided. Follow Section

VI, Paragraph A and Section VIII ‘Electrical’ of

these instructions to install and wire the ow 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

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 ll.

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 ow control valve prevents

ow through the system unless the circulator is

operating. Flow control valves are used to prevent

gravity circulation or “ghost ows” in circulator

zone systems through zones that are not calling for heat.

in the system, the old expansion tank can generally

Table 14: Fitting and Valve Equivalent Length

Copper Fitting and Sweat Valve Equivalent Length (Ft)

Fitting or Valve Description

90° Elbow 2.5 3.0 4.0 5.5 45° Elbow 1.0 1.2 1.5 2.0

Tee (through ow) 0.5 0.6 0.8 1.0 Tee (Branch ow) 4.5 5.5 7.0 9.0

Diverter Tee (typical) 23.5 25.0 23.0 23.0 Gate Valve 0.3 0.4 0.5 0.7 Globe Valve 25.0 36.0 46.0 56.0 Angle Valve 5.3 7.8 9.4 12.5 Ball Valve (standard port) 4.3 7.0 6.6 14.0 Ball Valve (full port) 1.9 1.4 2.2 1.3 Swing Check Valve 4.5 5.5 6.5 9.0 Flow-Check Valve (typical) 54.0 74.0 57.0 177.0

Buttery Valve 2.7 2.0 2.7 4.5

NOTE: Table 14 is provided as reference to assist in piping design and species equivalent length of typical piping ttings and valves.

Copper Pipe or Valve Size

1 1¼ 1½ 2

Threaded Fitting and Valve Equivalent Length (Ft)

Fitting or Valve Description

90° Elbow 2.6 3.5 4.0 5.2 Long Radius

Elbow (45° or 90°)

Tee (through ow) 1.8 2.3 2.7 3.5 Tee (Branch ow) 5.3 6.9 8.1 10.0

Close Return Bend 4.4 5.8 6.7 8.6 Gate Valve (full open) 0.7 0.9 1.1 1.4 Globe Valve (full open) 30.0 39.0 46.0 59.0 Angle Valve (full open) 13.0 17.0 20.0 26.0 Swing Check Valve

(full open) Flow-Check Valve

(typical)

(cont’d)

Black Threaded Pipe or

Valve Size

1 1¼ 1½ 2

1.4 1.8 2.2 2.8

8.7 12.0 13.0 17.0

42.0 60.0 63.0 83.0

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

rell 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 lled 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, ux 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 presence 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 rell is not recommended, however, if such rell is employed, a water meter must be added to evaluate the makeup water volume taken after initial ll 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 Fe3O4) forms as the result of continuous electrolytic corrosion in any 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.

VI. Water Piping and Trim C. Standard Installation Requirements (continued)

Figure 20: Near Boiler Piping - Heating Only

VI. Water Piping and Trim C. Standard Installation Requirements (continued)

Figure 21: Near Boiler Piping - Heating Plus Indirect Water Heater

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 ow 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 ow 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

Number of Units

Boiler Model

APX425 2½” 3” 3” 4” 5” 5” 5” APX525 3” 4” 4” 5” 5” 6” 6” APX625 3” 4” 5” 5” 6” 6” 6” APX725 4” 4” 5” 6” 6” 8” 8” APX825 4” 5” 5” 6” 6” 8” 8”

2 3 4 5 6 7 8

Recommended Minimum Common

Water Manifold Size (NPT)

Figure 22A: Isolation of the Boiler From Oxygenated Water with A Plate Heat Exchanger

(IWH Piped as Part of Boiler Piping)

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 specic details.

c. Selection criteria for individual module (boiler)

space heating and/or DHW circulators.

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 ow

and combined coil pressure drop and the zone piping total equivalent length. Refer to Alliance SL™ Indirect

Water Heater literature for specic model coil ow and

pressure drop. Refer to Figures 23A and 23B.

VI. Water Piping and Trim E. Multiple Boiler Installation Water Piping (continued)

Figure 23A: Multiple Boiler Water Piping w/Domestic Hot Water Heater (Page 1 of 2)

NOTICE

Installing a low water cutoff in the system piping

of multiple boilers is strongly recommended and

may be required by local codes.

NOTICE

Figure 23B: Multiple Boiler Water Piping w/Domestic Hot Water Heater (Page 2 of 2)

VI. Water Piping and Trim E. Multiple Boiler Installation (continued)

Installing a low water cutoff in the system piping

of multiple boilers is strongly recommended and

may be required by local codes.

VII. Gas Piping

WARNING

Explosion Hazard. Failure to properly pipe gas supply to boiler may result in improper operation and damage to the boiler or structure. Always assure gas piping is absolutely leak free and of the proper size and type for the connected load.

An additional gas pressure regulator may be needed. Consult gas supplier.

NOTICE

Size corrugated stainless steel tubing (CSST)

to ensure proper capacity and minimize ow

restrictions.

A. Size gas piping. Design system to provide

adequate gas supply to boiler. Consider these factors:

1. Allowable pressure drop from point of delivery to boiler. Maximum allowable system

pressure is ½ psig (3.4 kPa). Actual point of delivery pressure may be less; contact gas supplier for additional information. Minimum gas valve inlet pressure is printed on the rating label located in the boiler’s vestibule compartment.

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ttings.

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 ttings.

4. Specicgravityofgas. Gas piping systems for

gas with a specic gravity of 0.60 can be sized directly from Table 16A and gas with a specic

gravity of 1.5 can be sized from Table 16B, unless

authority having jurisdiction species a gravity factor be applied. For other specic gravity, apply gravity factor from Table 18. If exact specic

gravity is not shown choose next higher value.

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.

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

Inside

Diameter, In.

Length of Pipe, Ft.

10 20 30 40 50 60 70 80 90 100

Inlet Pressure 13.8 in wc (3.4 kPa) or less; 0.5 in wc (0.12 kPa) Pressure Drop

Nominal Pipe

Size, In.

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.

Inside

Diameter, In.

Length of Pipe, Ft.

10 20 30 40 50 60 70 80 90 100

VII. Gas Piping (continued)

For materials or conditions other than those listed

above, refer to National Fuel Gas Code, ANSI Z223.1/

B. Connect boiler gas valve to gas supply

system.

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.

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

Inside

Diameter, In.

Length of Pipe, Ft.

10 20 30 40 50 60 70 80 90 100

Inlet Pressure 11.0 in wc (2.7 kPa); 0.5 in wc (0.12 kPa) Pressure Drop

Nominal Pipe

Size, In.

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.

Inside

Diameter, In.

Length of Pipe, Ft.

10 20 30 40 50 60 70 80 90 100

Table 17: Equivalent Lengths of Standard Pipe Fittings & Valves (ft)

Nominal

Pipe Size,

Inc.

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

Inside

Diameter,

In.

Valves (Screwed) - Fully Open Screwed Fittings

Gate Globe Angle

Swing

Check

45°

Elbow

90°

Elbow

180 Close

Return Bend

90 Tee Flow

Through

Run

90 Tee, Flow

Through

Branch

VII. Gas Piping (continued)

Table 18: Specic Gravity Correction Factors

Specic

Gravity

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

Correction

Factor

Specic

Gravity

Correction

Factor

WARNING

Explosion Hazard. Failure to use proper thread compounds on all gas connectors

may result in leaks of ammable 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 liqueed 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:

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”.

Boiler

Model

APX425 APX525 APX625 APX725 APX825 103259-02

Miscellaneous

Parts Carton

102942-05

104520-01

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.

Table 19: Min./Max. Pressure Ratings

Boiler

Model

No.

APX425 13.5 4.0

APX525

APX625

APX725

APX825

Natural/LP

Gas Max.

Pressure

(in. w.c.)

13.5 4.5

Natural Gas

Min. Pressure

Inlet to Gas Valve

(in. w.c.)

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.

LP Gas

Min. Pressure

Inlet to Gas

Valve

(in. w.c.)

11.0

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 non-

corrosive leak detector solution.

DANGER

Explosion Hazard. Do not use matches, candles,

open ames or other ignition source to check for

leaks.

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

specic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).

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

red.

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

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

junction box on the left side of the vestibule. The terminal block TB-1 in conjunction with terminal

screw identication 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.

are located in the

VIII. Electrical (continued)

3. The terminal block TB-2

terminal screw identication label is attached to

the junction box front and located inside Sage2.1 Control compartment on the left side.

in conjunction with

4. Theconnectionsare(listedidentication

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 uorescent

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.

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.

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.

Table 20: Boiler Current Draw

Model Number

APX425 < 7

APX525 < 6

APX625 < 8

APX725 < 8

APX825 < 8

Nominal Current

(amps)

E. Flow Switch Wiring

Apex boilers include factory provided ow switch to

prevent boiler overheating. See Section VI, Water Piping and Trim for pertinent details.

The ow 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 ow 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 ow switch for specic details and Figure

26 “Ladder Diagram” and Figure 27 “Connection Diagram” in this section.

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

VIII. Electrical (continued)

Figure 27: Wiring Connections Diagram

VIII. Electrical (continued)

Figure 28A: Modied Wiring For DHW Priority When Using Low Flow Circulator Piped Off System Header -

Heating (with Central Heating Circulators) Plus Alternately Piped Indirect Water Heater

ALVES)

(SEE NOTE)

AT 0.9 AMPS (40VA REQ'D

W/ HEAT ANTICIPATOR SET

2 WIRE (24V) THERMOSTATS

FOR EVERY 3 ZONE VALVES)

TACO ZONE VALVES

AT 0.5 AMPS (40VA REQ'D

W/ HEAT ANTICIPATOR SET

2 WIRE (24V) THERMOSTATS

FOR EVERY 4 ZONE V

ZONE VALVES

HONEYWELL V8043E

AT 0.3 AMPS (40VA REQ'D

W/ HEAT ANTICIPATOR SET

2 WIRE (24V) THERMOSTATS

FOR EVERY 4 ZONE VALVES)

ZONE VALVES

#1361-102

WHITE ROGERS

231

FIELD INSTALLED

(SEE NOTE)

40VA TRANSFORMER

YE YE

VIII. Electrical (continued)

(SEE NOTE)

FLAIR "VJ"

ZONE VALVES

AT 0.9 AMPS (40VA REQ'D

W/ HEAT ANTICIPATOR SET

2 WIRE (24V) THERMOSTATS

POWER

SUPPLY

120/60/1

TO SAGE2

HEATING T-STAT

4 5

FOR EVERY 6 ZONE VALVES)

Heating (with Central Heating Zone Valves) Plus Alternately Piped Indirect Water Heater

Figure 28B: Modied Wiring For DHW Priority When Using Low Flow Circulator Piped Off System Header -

SEPARATE GROUND IS MADE IN THE ZONE CIRCUIT.

GROUNDED ON EI AND CANADIAN MODELS AND THE ZONE CIRCUIT MAY NOT OPERATE IF A

CORRECT BY SWITCHING X1 AND X2 OR X3 AND X4. ALSO, BOILER SECONDARY SIDE (24V) IS

TRANSFORMER ON TACO AND FLAIR ZONE VALVE CIRCUITS. IF CROSS-PHASING OCCURS,

CHECK FOR CROSS-PHASING BETWEEN BOILER TRANSFORMER AND FIELD SUPPLIED

NOTE:

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)

VIII. Electrical (continued)

Sequence of Operation

Tekmar 265 Based Control System (or equal)

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 re either one or more boilers in either parallel or sequential ring 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 ring 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.

Sequence of Operation

Tekmar 264 Based Control System (or equal)

Figure 30B: Multiple Boiler Wiring Diagram w/Tekmar 264 Control

VIII. Electrical (continued)

The Tekmar 264 Control (or equal) can control up to four (4) boilers and an Indirect Water Heater by utilizing stage ring. When a call for heat is received by the Tekmar 264

Control, the control will re either one or more boilers in sequential ring 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 re the boilers to establish a setpoint temperature in the main for the Indirect

Heater using Priority. The Tekmar 264 Control will disable the stage ring 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 ring of the

boilers to establish equal operating time for each boiler stage.

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

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 Comments

Wire the header sensor to low voltage terminal strip terminals “Header sensor”.

Install and wire the Header

Sensor

Install Ethernet Cables

between boilers

3 Apply Power to All Boilers

Set Unique Boiler

Addresses

5 Enable 1 Boiler Master

6 Power Down All Boilers

Power Up Master

Sequencer

“Enabled” Boiler First

8 Power Up Other Boilers

9 Conrm Communication

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.

When two boiler’s addresses are the same undesirable simultaneous operation occurs.

Enable only one Sage2.1 Control’s Sequencer Master.

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 conrm all boilers have unique

addresses.

NOTE

WARNING

IX. System Start-up

WARNING

Explosion Hazard. Asphyxiation Hazard. Electrical Shock Hazard. Start-up of this boiler should be undertaken only by trained and skilled

personnel from a qualied 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. Conrmallelectrical,waterandgas

supplies are turned off at the source and that

vent is clear of obstructions.

C. Conrmthatallmanualshut-offgasvalves

between the boiler and gas source are closed.

D. If not already done, ush the system to remove

sediment, ux 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.

F. Prepare to check operation.

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

rst 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 rst 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-red

appliances.

4. Turn on gas supply to the boiler gas piping.

5. Open the eld installed manual gas shut-off valve

located upstream of the gas valve on the boiler.

6. Conrm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.

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. Conrmthattheboilerandsystemhaveno

water leaks.

DANGER

Explosion Hazard. Do not use matches, candles,

open ames 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 lled with air.

Even if the gas line has been completely purged of air,

IX. System Start-up (continued)

Apex Series Operating Instructions

Figure 34: Operating Instructions

IX. System Start-up (continued)

Status Control Action

Initiate Power-up

This state is entered when a delay is

Standby Delay

Standby

Safe Startup

Drive Purge

Prepurge

Drive Light-off

Pre-ignition

Test

Pre-ignition

Direct

Ignition

Running

Postpurge

Lockout

it may take several tries for ignition before a ame 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 ame has been established for the rst time, subsequent calls for burner operation should result in a ame on the rst try.

I. Check Burner Flame

Inspect the ame visible through the window. On high

re the ame should be stable and mostly blue (Figure

35). No yellow tipping should be present; however,

intermittent ecks of yellow and orange in the ame 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.

needed before allowing the burner control to be available and for sensor errors.

Boiler is not ring. There is no call for heat or there is a call for heat and the temperature is greater than setpoint.

Tests ame circuit then checks for ame

signal.

Driving blower to purge rate setting and waiting for the proper fan feedback.

Purges the combustion chamber for the

10 second purge time.

Driving blower to light-off rate setting and waiting for the proper fan feedback.

Tests the safety relay and veries that

downstream contacts are off.

Energizes the igniter and checks for ame.

Opens main fuel valve and attempts

to ignite the main fuel directly from the

ignition source.

Normal boiler operation. Modulation rate

depends on temperature and setpoint selections and modulating control action.

Purges the combustion chamber for the

30 second purge time.

Prevents system from running due to a

detected problem and records fault in

Lockout History.

WARNING

Asphyxiation Hazard. The outlet pressure for

the gas valve has been factory set and requires no eld 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.

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uetemperaturesensor from vent

connector (see Figure 9 on page 22) and insert

combustion analyzer probe through ue temperature

sensor silicon cap opening. If required, also remove

the ue temperature sensor silicon cap and insert the analyzer probe directly into ue sensor port.

Reinstall the sensor and the cap upon combustion testing completion.

2. Verify O2 (or CO2) and CO are within limits

specied in Table 21 (natural gas) or Table 22 (LP gas) at both high and low re as described in the

following steps.

Table 21: Typical Combustion Settings, Natural Gas

Boiler

Model

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

High Fire Low Fire

% CO

% O2% CO2% O

CO,

PPM

Less than

100 PPM

IX. System Start-up (continued)

Figure 35: Burner Flame

Table 22: Typical Combustion Settings,

LP Gas

Boiler

Model

APX425 11.4 - 9.5 3.5 - 6.5 11.4 - 9.1 3.5 - 7.0

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

High Fire Low Fire

% CO

% O

% CO

CO,

PPM

Less than

100 PPM

% O

a. Lock boiler in high re and allow boiler to

operate for approximately 5 minutes before taking combustion readings. To lock boiler in

high re, 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 re.

WARNING

The offset screw has been factory set using precision instruments and must never be adjusted in the eld 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 re O

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 re O2 is too high (CO2 is too low),

decrease O2 (increase CO2) by turning the

is too low (CO2 is too high),

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 re and allow boiler to

operate for approximately 5 minutes before taking combustion readings. Press “Low” to

lock boiler in low re.

WARNING

Asphyxiation Hazard. Offset screw is adjusted

at the factory to the specication. DO NOT touch the offset screw if measured low re O2 (or

CO2) is within limits specied in Table 21 or 22.

e. If low re 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 re O

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

is too high (CO2 is too low),

IX. System Start-up (continued)

Refer to Figure 36 for location of offset screw. Verify CO is less than 100 ppm.

3. Reinstalluetemperaturesensorwith silicone

cap into two-pipe vent adapter.

4. Return boiler to normal operating mode by

pressing “Auto”.

M. Checking / Adjusting Gas Input Rate

1. Turn off gas supply to all appliances other than

gas-red boiler.

2. Locktheboilerinhighre,following Step 3a

in Paragraph L.

3. Clock gas meter for at least 2 revolutions of

the dial, typically labeled ½ or 1 cubic foot per revolution on the gas meter.

4. Determinegasow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 ow rate:

3600 sec/hr ÷ 36 sec/cu ft = 100 cu ft/hr

5. Obtain gas-heating value (BTU per cubic foot)

from gas supplier.

6. Multiply hourly gas ow 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 ow 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.

10. Return boiler to normal operating mode by

pressing “Auto”.

11. Return other gas-red appliances to previous

condition of use.

N. Test Safety Limits Controls

1. Test the ignition system safety shut-off by

disconnecting the ame sensor connector (black plug with orange wire) from the ame ionization

electrode. See Figure 27. The boiler must shut

down and must not start with the ame sensor

disconnected.

2. Testtheowswitch by disabling the primary

loop circulator. The boiler must not start if ow is

not present.

3. Test any other external limits or other controls

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.

Q. Adjust Thermostats

Adjust the heating and indirect water heater thermostats

to their nal 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 eld converted to LP gas. Follow steps below for eld 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.

IX. System Start-up (continued)

WARNING

Explosion Hazard. Asphyxiation Hazard. This conversion should be performed by a

qualied 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 re, an

explosion or production of carbon monoxide may result causing property damage, personal

injury, or loss of life. The qualied 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 specied in this manual.

2. If conversion is being made on a new installation,

with the installation instructions supplied with the boiler. If an installed boiler is being converted, connect the new gas supply to the boiler, check for gas leaks, and purge the gas line up to the boiler in accordance with the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or Natural Gas and Propane Installation Code, CAN/CSA B149.1 or the requirements of the authority having jurisdiction.

3. Before attempting to start the boiler, make the

number of turns to the throttle screw called for in Table 23.

install the boiler in accordance

WARNING

Asphyxiation Hazard. The throttle adjustments shown in Table 23 are approximate. The

nal 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.

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.

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 ue 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.

Table 23: Approximate Number of Clockwise

Throttle Screw Turns for LP Conversion

Boiler

Model

APX425

APX525

APX625

APX825

Gas Valve

GB-057 HO

(¾” NPT)

GB-057 HO

(¾” NPT)

GB-ND057 D01 S00 XP

(¾” NPT)

Approximate Throttle

Screw Turns

1¾

Factory LP BuildsAPX725

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 rst

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.

7. A label sheet is provided with the boiler for

conversions from natural gas to LP gas. Once conversion is completed, apply labels as follows:

a. Apply the “Rating Plate Label” adjacent to the

rating plate.

b. Apply the “Gas Valve Label” to a conspicuous area

on the gas valve.

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.

S. Correcting Throttle Screw Mis-Adjustment

(if required)

Alpine boilers are re tested at factory and gas valve

throttle screws are preset. However, if boiler does not

start when rst 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 specied in Table 21 for natural gas or Table 22 for LP gas at both high re and low re.

WARNING

The throttle adjustment values shown in Table 24A and Table 24B are approximate. The

nal throttle setting must be found using a

combustion analyzer.

Table 24A: Approximate Throttle Screw Adjustment Values from Fully Closed Position, Natural Gas

Boiler

Model

APX425 4 & 3/4

APX525 4 & 3/4

APX625 6

APX725 10

APX825 7 & 1/2

Throttle Position (Number of Counter-

clockwise Turns from Fully Closed Position

Table 24B: Approximate Throttle Screw Adjustment Values from Fully Closed Position, LP Gas

Boiler

Model

APX425 3

APX525 3 & 3/4

APX625 6

APX725 10

APX825 7 & 1/2

Throttle Position (Number of Counter-

clockwise Turns from Fully Closed Position

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 deciency. 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 deciency, the following phenomena may be observed:

% CO

% CO2 will actually increase (% O2 will drop) as the throttle is turned clockwise

If the boiler appears to operate with air deciency, shut down the boiler and follow instructions in Paragraph

S “Correcting Throttle Screws Mis-Adjustment. Then, use a combustion analyzer to verify and adjust O CO2) and CO to values shown in Table 21 for natural gas or Table 22 for LP gas.

will actually drop (% O2 will increase) as the throttle is turned counter-clockwise

(or

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. Title Terminal Description

1 & 2

2 & 3 Is an Indirect Water Heater (IWH) providing a boiler heat demand?

5 & 6

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 Parameter Description

8 DHW

10 Sequencer Master Slave

Check

Wiring

System

Setup

Modulation

Setup

Pump Setup

Contractor

Setup

Manual Control

Central

Heat

Remote

4-20mA

7 & 8 Is a header sensor used? If yes, refer to step 10 below to activate this feature.

9 & 10

11 & 12

LWCO Plug Is a LWCO required? Check installation of the LWCO.

Warm Weather

Shutdown

Warm Weather

Shutdown Setpoint

Boiler Type

System Pump

Boiler Pump

Domestic Pump

Contractor Name

Address

Phone

Manual Speed

Control

Setpoint Ensure Setpoint, (ring rate target temperature) is correct for your type of radiation.

Setback

Setpoint

Setpoint Ensure Setpoint, (ring rate target temperature) is suitable for the IWH requirements.

Setback

Setpoint

Modulation Source

Setpoint Source Set to 4-20mA when a Energy Management system is sending a “remote” setpoint.

Is the heating thermostat connected? Insure this is “dry”, non-powered input.

Is an Outdoor Air sensor used? If no, select outdoor sensor type “not installed” under

system menu.

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.

Is a Flow Switch (where applicable) and/or External Limit used? Remember to remove

factory-installed jumper.

Selecting “Enable” will restrict boiler start during warm weather (only if an outdoor air

temperature sensor is installed).

Use this setting to adjust the temperature that the WWSD function will shut boiler off.

WARNING

Conrm that the correct boiler model is shown. Stop installation and contact factory if the wrong boiler model is shown.

Ensure that the pump parameter selections are correct for your heating system. Refer to Paragraph G. Adjusting Parameters, Pump Setup Menu for additional information.

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.

Use the “High and “Low” options to force the boiler to high re and low re for combustion testing.

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).

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.

Refer to Sequencer Master Setup Section X, G if multiple boilers are installed at this

site.

X. Operation

180 F

Boiler 1

Energy Save On Max Efficiency On

Standby

Status

Help

Adjust

Detail

A. Overview

1. Sage 2.1 Controller

The Sage 2.1 Controller (Control) contains features and capabilities which help improve heating system operation,

and efciency. By including unique capabilities, the Control can do more, with less eld wiring, and fewer aftermarket

controls and components – improving the operation of both new and replacement boiler installations.

2. Advanced Touch Screen Display

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 ue 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 ame 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

eld installation of ow 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

eld 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 leadlag 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 congured 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.

X. Operation B. Supply Water Temperature Regulation (continued)

11. Modbus Communication Interface

A factory congured 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

Status

Priority

1st Sequencer

2nd Domestic Hot

3rd Central Heat Central Heat call for heat is on and

4th Frost

5th Warm

6th Standby There is no demand detected.

2. Setpoint Purpose

3. Central Heat Setpoint

Screen

Display

Control

Water

Protection

Weather

Shutdown

(WWSD)

Boiler Responding to:

The boiler is connected to the peerto-peer network. The boiler accepts demand from the Sequencer Master.

DHW call for heat is on and selected 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.

there is no DHW demand or DHW priority time has expired.

Frost Protection is active and there is no other call for heat. Frost protection will be a higher priority than Sequencer Control if the Sequence Master has no active call for heat.

WWSD is active and the boiler will not respond to central heat demands. DHW demand is not blocked by

WWSD.

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.

Upon a Central Heat call for heat the setpoint is either 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 efciency 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 satised for longer than the Boost Time

minutes. The Boost feature increases the operating temperature setpoint by 10°F (5.6°C) every 20 minutes

(eld adjustable) the central heat demand is not satised. This process will continue until heat demand is satised

(indoor air is at desired temperature). Once the heat

demand is satised, 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 input rating greater than or equal to 400,000 BTU/hr, ASME

Boiler and Pressure Vessel Code requires a ow switch in

lieu of low water cutoff. ALSO ADHERE TO ALL LOCAL CODE REQUIREMENTS. Contact your local code inspector prior to installation.

The ow switch is an operating control, which must be used

in conjunction with supply water temperature high limit. It is factory provided with Apex boilers and must be installed as part of near boiler piping (see Section VI ‘Water Piping and Trim’ of these instructions).

The control shuts down the boiler when the water ow in

boiler primary loop is either non-existent or too low. This ensures the boiler shutdown to prevent boiler overheating.

When water ow is restored to a boiler-specic minimum ow value (see Table 12 ‘Flow Range requirement Through Boiler’) the switch will detect the ow and restart boiler

automatically.

If the ow switch opens, the boiler will shut down and an

open limit indication and error code is provided.

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 ve times the

boiler manual reset Hard Lockout is set. This condition is the result of incorrectly attaching the supply and return piping.

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 ow switch is installed, any

additional external limit must be wired in series with the

ow 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, ow 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 ue gas temperature sensor located in the vent connector. If the ue temperature

exceeds 184°F (84.4°C), the control begins to reduce the

maximum blower speed. If the ue temperature exceeds

194°F (90.0°C), a forced boiler recycle results. If the

ue temperature exceeds 204°F (95.6°C), the control

activates a manual reset Hard Lockout.

8. Ignition Failure

The Control monitors ignition using a burner mounted

ame sensor. In the event of an ignition failure:

• Model APX425 - the control retries 5 times and

then goes into soft lockout for one hour.

• Models APX525, APX625, APX725 and APX825 - the

control retries 1 time and then goes into hard lockout. Manual reset is required to resume boiler operation.

9. Central Heating System Frost Protection

When enabled, Frost Protection starts the boiler and

system pump and res the boiler when low outside air

and low supply water temperatures are sensed. The Control provides the following control action when frost protection is enabled:

Table 26: Frost Protection

Device

Started

Boiler & System

Pump

Boiler Supply Water < 38°F (3.3°C) Supply Water > 50°F (10°C)

Supply Water < 45°F (7.2°C)

Start

Temperatures

Outside Air < 0°F (-18°C)

Stop

Temperatures

Outside Air > 4°F (-15°C)

Supply Water > 50°F (10°C)

FROST PROTECTION NOTE

The Control helps provide freeze protection for the boiler

water. Boiler ue 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.

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 rst to start and the Slave boilers are

started in sequential order (1,2,3,…) until the demand

is satised. 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 ring 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 ue gas temperatures and modies the Sequence Master’s ring rate demand to help avoid individual boiler

faults, minimize boiler cycling and provide heat to

the building efciently.

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 rst during winter months and then selected to

run last for the remainder of the year.

6. Multiple Demands

7. Shared or Isolated DHW Demand

8. DHW Two boiler Start

9. Optimized Boiler Modulation

10. Innovative Condensing Boiler Control

11. Advanced Boiler Sequencing

12. Stop All Boilers

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.

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, res to satisfy the DHW setpoint.

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.

Boiler ring rate is managed to increase smoothly as

boilers are started. For example, when a second boiler is

started the initial ring rate is 100%/2 or 50%, when the third boiler is started the ring rate starts at 200%/3 or

66%. After the initial start, the Sequence Master develops

a unison ring rate demand based on it’s setpoint and

sensed header temperature.

During low loads, the Sequence Master limits ring rates

to a ‘Base Load Common Rate” to ensure peak operating

efciency. Lower ring rates boost efciency by helping increase the amount of ue 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.

After there is a Call For Heat input, both header water

temperature and boiler ring 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 ring 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.

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) (eld 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 Description

Boiler 1

Supply

140 F

Setpoint

Rate

Priority:

Status:

140 F

Standby Standby

Priority: Standby

Status:

Standby

(burner Off, circulator(s) Off)

Boiler is not ring and there is no call for heat, priority equals standby. The boiler is ready to respond to a call for heat.

Boiler 1

Supply

140 F

Setpoint

Rate

Priority:

Status:

Boiler 1

Supply

Setpoint

Rate

Priority:

Status:

140 F

Central Heat Standby

132 F 140 F

98%

Central Heat Prepurge 10

Central Heat

Priority:

Status:

Standby

Priority:

Status:

Prepurge

(burner Off, circulator(s) On)

Boiler is not ring. There is a Central Heat call for heat and the Supply temperature is greater than setpoint minus the “Diff Below”.

When supply temperature drops burner demand continues with following Status shown:

Safe Startup: Flame circuit is tested.

Drive purge: The blower is driven to the fan purge speed. Prepurge: After the blower reaches the fan purge speed setting the 10 second combustion chamber purge is conducted.

Boiler 1

Supply

132 F

Setpoint

Rate

Priority:

Status:

Boiler 1

Supply

Setpoint

Rate

Priority:

Status:

Boiler 1

Supply

Setpoint

Rate

Priority:

Status:

140 F

89%

Central Heat Direct Ignition

132 F 140 F

100%

Central Heat Running

132 F 180 F

100%

Domestic Hot Water

Running

Central Heat

Priority:

Status:

Direct

ignition

Priority:

Status:

Running

Priority: Domestic Hot Water

Status:

Running

After purge time is complete the following Status is shown: 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

conducted.

Pre-ignition: Spark is energized and it is conrmed that no ame is present

Direct Ignition: Spark and Main fuel valve are energized.

(burner On, circulator(s) On)

After ame is proven normal boiler operation begins. Modulation rate depending

on temperature and setpoint selections and modulating control action.

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.

Priority:

Standby

Status:

Post-purge

Priority:

Standby

Status:

Standby

Delay

Priority:

Standby

Status:

Lockout

(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.

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

Efciency 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 Efciency On” appears when the boiler return temperature has been reduced low enough to cause energy saving ue gas condensation.

Menu Button

Status

Detail

Help

Adjust

Boiler 1

180 F

Standby Energy Save On

Max Efficiency On

Home Screen

The Home Screen Menu Buttons connect the displays four main display groups; Status, Detail, Help and Adjustment Screens.

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 Active

Boiler 1

Supply

180 F

Setpoint

180 F

Rate

Priority:

Central Heat

Status: Standby

Fault

Status Screen

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.

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

Status

Detail

Help

Adjust

Boiler 1

180 F

Standby Energy Save On

Max Efficiency On

Boiler 1

Supply

Setpoint

180 F 180 F

Rate

Priority:

Status: Standby

Status Screens

(see Figure 38)

Central Heat

Domestic

Hot Water

Outdoor

Reset Curve

Detail Menu

(see Figure 39)

Active Faults

Lockout History

Service

Contract

Help Menu

(see Figure 44)

Sequencer

Setup

Boiler Size

Setup

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.

Boiler 1

Supply

Setpoint

Rate

Priority:

Status: Standby

180 F 180 F

Central Heat

Supply

Return

Stack

Rate

Status

180 F 160 F 147 F

40 %

Trends

Flame

2.5 hour trend

Flame

5 minute trend

Supply / Return

Firing Rate

Heat Demand

Central Heat On

Domestic Hot Water Off

Sequence Master Off

Frost Protection Off

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.

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.

Pump Status/Cycles

System On 98

Boiler On 23

DHW Off 0

Frost Protection On Exercise On

Figure 37: Status Screens

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.

Boiler 1

Supply

180 F

Setpoint

180 F

Rate

Priority: Central Heat

Status: Standby

Active

Fault

Boiler Cycles/Hours

Boiler Cycles

Run Time Hours

2000

800

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.

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

Trends

Flame

2.5 hour trend

Flame

5 minute trend

Supply / Return

Firing Rate

Data Logging Real time graphic trends allow users to observe process

changes over time providing valuable diagnostic

information. For example,  ame current performance

over start up periods and varying loads can be an indication of gas supply issues. Additionally, supply and return temperature dual pen trends brings a focused look at heat exchanger and pump performance. For example, studying a differential temperature trend may indicate pump speed settings need to be changed.

Boiler Cycles/Hours

Boiler Cycles

Run Time Hours

2000

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.

X. Operation F. Viewing Boiler Status (continued)

Central Heat

On Point - 7 F

Setpoint

Off Point +

5 F

Firing Rate 22% Setpoint: Outdoor Reset

180 F

Supply

Outdoor Reset

Outside Air

W a

180

130 110

0 70

Setpoint 164 F

Outside Air 16 F

Status: Enabled

1. Status Screens (continued)

Pump Status/Cycles

System On 98

Boiler On 23

DHW Off 0

Frost Protection On 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.

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.

Heat Demand

Central Heat On

Domestic Hot Water Off

Sequence Master Off

Frost Protection Off

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.

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

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.

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.

Networked Boilers:

Sequencer

Header

132 F

Setpoint

Rate

Priority:

180 F 100%

Domestic Hot Water

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.

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.

Networked Boilers

Boiler 1 Lead 50% Firing

Boiler 2 50% Firing

Boiler 3 0 % Available

Boiler 4 0 % Available

Sequence Status:

Slave boiler status is provide as follows:

Available:

Add Stage:

Running:

On Leave:

Recovering:

Disabled:

Boiler is ready and waiting to be started by the Sequencer Master.

Boiler has begun the start sequence but has not yet reached the boiler running status.

Boiler is running.

Boiler has left the network to service a DHW demand.

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.

Boiler has a lockout condition and is unable to become available to the Sequencer Master.

Firing Rate:

Demanded firing rate is provided.

X. Operation G. Changing Adjustable Parameters (continued)

Active

Fault

Adjustment Mode

For Service Contact:

CONTRACTOR NAME

ADDRESS LINE 1 ADDRESS LINE 2 PHONE NUMBER

Access Level: Installer

Password required

Installer Password = 76

Warning! Only Qualified

Technicians Should Adjust

Controls, Contact Your

Qualified Heating Professional

Press 5-digit display to

Input Password

Press Save to enter password

000

RESC

5432

B S

0987

Press 5-digit display to

Input Password

076

After inputting the

password press to enter password

After password is Saved

These buttons access

Adjust mode screens

Service Contact Adjust

Save Adjust

Adjust

G. Changing Adjustable Parameters

1. Entering Adjust Mode

The Control is factory programmed to include basic modulating boiler functionality. These settings are password protected to discourage unauthorized or accidental changes to settings. User login is required to view or adjust these settings:

- Press the “Adjust” button on the “Home” screen.

- Press the “Adjust” button on the Adjust Mode screen or Press 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.

2. Adjusting Parameters

Editing parameters is accomplished as follows:

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

Figure 39: Adjust Mode Screens

Central Heat

CH Setpoint

180

Value to be edited

(blinks while editing)

Cancel edit

Edit Value

Press the button to cancel newly edited value and go back to the original

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.

X. Operation G. Changing Adjustable Parameters (continued)

Pump Setup

- More -

Manual Control

Contractor

Setup

System

Setup

Modulation

Setup

Outdoor

Reset

Remote 4-20mA

Central

Heat

Domestic

Hot Water

Sequence

Master

Sequence

Slave

System

Setup

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):

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

“Press”

Factory

Setting

Fahrenheit

button to access the following parameters:

Range /

Choices

Fahrenheit,

Celsius

4 0-14

8 0-14

Not Installed,

Wired

Wireless

Enabled Enable/Disable

0 Secs 0-900 Secs

Disabled Enable/Disable

70°F 0-100°F

Parameter and Description

Temperature Units

The Temperature Units parameter determines whether temperature is represented in units of Fahrenheit or Celsius degrees.

Display Brightness

Display brightness is adjustable from 0 to 14.

Display Contrast

Display contrast is adjustable from 0 to 14.

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 res when low outside air, supply and

return temperatures are sensed as follows:

Device

Started

Boiler & System Outside Air < 0°F (-18°C) Outside Air > 4°F (-16°C)

Start

Temperatures

Stop

Temperatures

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 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 satised. The boiler will still start in response to a Domestic Hot Water call for heat.

Warm Weather Shutdown Setpoint

The Warm Weather Shutdown (WWSD) Setpoint used to shutdown the boiler when enabled by the “WWSD Enable” parameter.

X. Operation G. Changing Adjustable Parameters (continued)

Modulation

Setup

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”

Factory Setting

See Table

button to access the following parameters:

Range /

Choices

Boiler Type

Boiler Size Setup

To verify the boiler size selection, a qualied technician should do the following:

1. Check boiler’s label for actual boiler size.

See Table 28

Minimum to

Maximum

Modulation

Minimum to

Maximum

Modulation

Minimum

- 100 to

Maximum

See Table 28

2. Set “Boiler Type” to match actual boiler size.

3. Select “Conrm”.

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 denes 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 denes 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.

Minimum Modulation

This parameter is the lowest modulation rate the Control will go to during any call for heat.

Lightoff Rate

This is the blower speed during ignition and ame stabilization periods. Non-adjustable on

models APX625 and APX725.

Parameter and Description

Table 28: Parameters Changed Using the Boiler Type Parameter Selections:

Sage2.1 Control Repair Part 104472-01 104472-04 105008-02 105008-01 105008-02 105008-01 104472-04

Altitude 0 - 4500 ft. 0 - 2000 ft. 0 - 4500 ft.

Boiler Type

Maximum Light-off Rate (RPM) 4000 4000 2500 4000 2500 4000 4000 4000

Maximum Modulation Rate (RPM)

Minimum Modulation Rate (RPM)

Absolute Maximum Modulation Rate (RPM)

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.

425

-07

7600 5900 5050 4800 4350 4400 5200 5150

2100 1400 1600 1600 1400 1450 1200 1200

8500 6550 5900 6300 5500 5850 5900 5600

525

-07

625N

-02

625P

-02

725N

-02

725P

-02

825N

-05

825P

-05

X. Operation G. Changing Adjustable Parameters (continued)

Pump Setup

“Press”

Factory Setting Range / Choices Parameter and Description

Central Heat,

Optional Priority

Any Demand

Primary

Loop Pipe

IWH

button to access the following parameters:

System Pump run pump for:

Activates the system pump output according to selected function.

Never,

Any Demand,

Central Heat,

No Priority,

Central Heat,

Optional Priority

Any Demand,

Central Heat, off

DHW demand

Never,

Primary Loop

Piped IWH,

Boiler Piped IWH

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 ow through boiler within limits shown in Table 12.

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 ow 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).

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.

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.

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)

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 Enabled

Indirect Water Heater

Pump Parameter Selections:

System Pump =

Boiler Pump =

DHW Pump = Boiler Piped IWH Never

Explanation:

Make sure indirect water heater and DHW pump are sized to maintain ow 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 satised 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.

“Boiler Piped”

Central Heat,

No Priority

Central Heat,

Off DHW Priority

Boiler 2

Never

Any

demand

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)

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 Enabled

Indirect Water Heater

Pump Parameter Selections:

System Pump =

Boiler Pump = Any demand

DHW 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.

“Primary Piped”

Central Heat,

Optional Priority

Primary Loop

Piped IWH

Boiler 2

Never

Any

demand

Never

Multiple Boilers, IWH piped to primary, system pump required to run for any call for heat

Sequencer Master

(Boiler 1)

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 Enabled

Indirect Water Heater

Pump Parameter Selections:

System Pump = Any demand Never

Boiler Pump = Any demand Any demand

DHW Pump =

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.

“Primary Piped”

Primary Loop

Piped IWH

Boiler 2

Never

X. Operation G. Changing Adjustable Parameters (continued)

Contractor

Setup

Manual Control

“Press”

button to access the following parameters:

Contractor Name

Press box to input contractor information.

Bill Smith

Save

Press SAVE button to store revisions.

For Service Contact:

12 Victory Lane

Plainview, New York

516 123-4567

Example Screen

Enter Contractor Information

Bill Smith

Use Up and DOWN Arrows for More

Exit Screen without Saving

Clear Entire Field

Backspace

Save Field and Exit

Factory Setting Range / Choices Parameter and Description

Contractor Name User dened Contractor Name

Address Line 1 User dened Contractor Address Line 1

Address Line 2 User dened Contractor Address Line 2

Phone User dened Contractor Phone

Bill Smith

“Press”

button to access the following screen:

The Manual Speed Control speed screen allows the technician to set ring rate at low or high speed for combustion testing.

Manual Speed Control

press to change mode

Low

“Press” “Low” to select

manual firing rate control

and Minimum firing rate %

0 RPM 0%

Status Auto

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)

Domestic

Hot Water

Central

Heat

button to access the following parameters:

Factory

Setting

180°F

(82.2°C)

170°F

(76.7°C)

5°F

(2.8°C)

7°F

(3.9°C)

3 1 to 5

Range / Choices Parameter and Description

80°F to 190°F

(26.7°C to 87.8°C)

80°F to 190°F

(26.7°C to 87.8°C)

(1.1°C to 5.6°C)

(1.1°C to 17°C)

2°F to 10°F

2°F to 30°F

“Press”

Central Heat Setpoint

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 setback setpoint shifts the reset curve to save energy while home is in a reduced room temperature 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.

Central Heat Diff Above

The boiler stops when the water temperature rises ‘Diff Above’ degrees above the setpoint.

Central Heat Diff Below

The boiler starts when the water temperature drops ‘Diff Below’ degrees below the setpoint.

Response Speed

This parameter adjusts the Central Heat temperature controller Proportion Integral Derivative (PID) values. Higher values cause a larger ring rate change for each degree of temperature change. If set too high ring rate “overshoots” required value, increases to high re causing the temperature to exceed the “Diff Above” setpoint and cycle the boiler unnecessarily. Lower values cause a smaller ring rate change for each degree of temperature change. If set too low, the ring rate response will be sluggish and temperature will wander away from setpoint.

“Press”

Factory

Setting

170°F

(76.7°C)

160°F

(71.1°C)

5°F

(2.8°C)

7°F

(3.9°C)

Enable Enable Disable

Minutes

3 1 to 5

Range / Choices Parameter and Description

80°F to 190°F

(26.7°C to 87.8°C)

80°F to 190°F

(26.7°C to 87.8°C)

(1.1°C to 5.6°C)

(1.1°C to 17°C)

30 to 120 Minutes

button to access the following parameters:

2°F to 10°F

2°F to 30°F

Domestic Hot Water Setpoint

The Domestic Hot Water (DHW) Setpoint parameter is used to create a minimum boiler water temperature setpoint that is used when DHW heat demand is “on”. When the DHW heat demand is not “on” (the contact is open or not wired) this setpoint is ignored.

Domestic Hot Water Thermostat “Sleep” or “Away” Setback Setpoint

Domestic Hot Water Diff Above

The boiler stops when the water temperature rises ‘Diff Above’ degrees above the setpoint.

Domestic Hot Water Diff Below

The boiler starts when the water temperature drops ‘Diff Below’ degrees below the setpoint.

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 congured 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.

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 ring rate change for each degree of temperature change. If set too high ring rate “overshoots” required value, increases to high re causing the temperature to exceed the “Diff Above” setpoint and cycle the boiler unnecessarily. Lower values cause a smaller ring rate change for each degree of temperature change. If set too low, the ring rate response will be sluggish and temperature will wander away from setpoint.

X. Operation G. Changing Adjustable Parameters (continued)

Outdoor

Reset

“Press”

Factory

Setting

Enabled Enable Disable

0°F

(-18°C)

70°F

(21.1°C)

110°F

(43.3°C)

130°F

(54.4°C)

0 Minutes

button to access the following parameters:

Range / Choices Parameter and Description

-40°F to 100°F

(-40°C to 37.8°C)

32°F to 100°F

(0°C to 37.8°C)

70°F to 190°F

(21.1°C to 87.8°C)

80°F to 190°F

(26.7°C to 87.8°C)

0-1800 Seconds

(0-30 Minutes)

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 dened 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 Do Not Calculate setpoint based on outdoor temperature Enable Calculate the temperature setpoint based on outdoor temperature using a reset

curve dened by Low Outdoor Temp, High Outdoor Temp, Low Boiler Water

Temp, Min Boiler Temp and Central Heat Setpoint and Boost Time parameters.

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.

Low Boiler Water Temperature

The Low Boiler Water Temperature parameter is the operating setpoint when the High Outdoor Temperature is measured. If the home feels cool during warm outdoor conditions, the Low Boiler Water Temperature parameter should be increased.

Minimum Boiler Temperature

The Minimum Boiler Temperature parameter sets a low limit for the Reset setpoint. Set this parameter to the lowest supply water temperature that will provide enough heat for the type radiation used to function properly. Always consider the type of radiation when adjusting this parameter.

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 satised 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)

Outdoor Air Temperature

-20 105-15 -10 -5

110

454020 25 30 35 55 60 65

15 50

145

115

150

120

140

135

130

125

155

190

160

195

165

185

180

175

170

200

Boost Maximum Off Point

= Central Heat Setpoint

minus Diff Above

Low Boiler Water Temp

Default = 110 F

High Outside Air Temp

Default = 70 F

10 F

Hot Water Setpoint

Minimum Water Temperature

Default = 130 F

TOD Setback Setpoint

Default = 170 F

Central Heat Setpoint

Low Outside Air Temp

=180 F & 0 F

Default Outdoor Air Reset Setpoint

(Shown Bold)

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)

Central Heat

Setpoint

180°F to 190°F

(82.2°C to 87.8°C)

160°F to 190°F

(71.1°C to 87.8°C)

130°F to 160°F

(54.4°C to 71.1°C)

Figure 40: Outdoor Reset Curve

Heating Element Type

Fan Coil

Convection

Baseboard

Fin Tube

Convective

Radiant

Baseboard

Central Heat

Setpoint

100°F to 140°F

(37.8°C to 60°C)

130°F to 160°F

(54.4°C to 71.1°C)

140°F to 160°F

(60°C to 71.1°C)

Heating Element Type

In Slab Radiant High

Mass Radiant

Staple-up Radiant Low Mass Radiant

Radiators

X. Operation G. Changing Adjustable Parameters (continued)

Remote 4-20mA

Sequence

Master

Sequence

Slave

“Press”

Factory

Setting

Local

130°F

(54.4°C)

180°F

(82.2°C)

* Only visible when Central Heat Setpoint Source is set to 4-20mA.

80°F (26.7°C) -

Central Heat

80°F (26.7°C) -

Central Heat

“Press”

Factory

Setting

Disable

Boiler Piped

Disabled

120 Secs 120 - 1200 Secs

195°F

(90.6°C)

50% 50% - 100%

3 1-5

Range / Choices Parameter and Description

button to access the following parameters:

Range /

Choices

Central Heat Modulation Source

Local,

4-20mA

Local,

4-20mA

Setpoint

This parameter enables the 4-20mA input to control ring rate and the thermostat input to control boiler on/off demand directly without using the internal setpoint. The 4-20mA selection is used to enable a remote multiple boiler controller to control the Sage2.1 Control:

Local: 4-20mA Input on Terminal 9 & 10 is ignored.

4-20mA 4-20mA Input on Terminal 9 & 10 is used to control ring Rate % directly.

Central Heat Setpoint Source

Sets the remote (Energy Management System) control mode as follows:

Local: Local setpoint and modulation rate is used. 4-20mA input on Terminal 9 & 10 is ignored.

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.

Central Heat 4-20mAdc Setup, 4 mA Water Temperature*

Sets the Central Heat Temperature Setpoint corresponding to 4mA for signal input on terminal 9 & 10. Current below 4mA is considered invalid, (failed or incorrect wired input).

Central Heat 4-20mAdc Setup, 20 mA Water Temperature*

Sets the Central Heat Temperature Setpoint corresponding to 20mA for signal input on terminal 9 & 10. Current above 20mA is considered invalid, (failed or incorrect wired input).

button to access the following parameters:

Enable,

Disable

Boiler Piped,

Primary Piped

Enable,

Disable

Central Heat

Setpoint,

195°F (90.6°C)

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 efciency, the ring rate is limited to an adjustable value. Boilers are kept at or below this ring 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 ring rate change for each degree of temperature change. If set too high ring rate “overshoots” required value, increases to high re causing the temperature to exceed the “Diff Above” setpoint and cycle the boiler unnecessarily. Lower values cause a smaller ring rate change for each degree of temperature change. If set too low, the ring rate response will be sluggish and temperature will

wander away from setpoint.

Parameter and Description

“Press”

Factory

Setting

None 1-8

Normal

Range / Choices Parameter and Description

Use Boiler First,

Use Boiler Last

button to access the following parameters:

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

Normal,

“Use Boiler First”; places the Slave in the lead permanently. ”Normal”; ring order follows boiler number (1,2,3,..) order. ”Use Boiler Last”; places the slave last in the ring 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.

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

efciency.

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

ttings 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.

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.

NOTICE

XI. Service and Maintenance (continued)

DANGER

Explosion Hazard. Electrical Shock Hazard. Burn Hazard. This boiler uses ammable 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 specied.

A. Continuously:

1. Keep the area around the boiler free from

combustible materials, gasoline and other ammable

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 ue 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 ow switch by disabling the boiler primary

loop circulator. The boiler must not start when there

is not water ow.

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.

XI. Service and Maintenance (continued)

CAUTION / ATTENTION

Electrical Shock Hazard. Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.

Au moment de l´entretien des commandes,

étiquetez tous les ls 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 ame sensor and

inspect them for oxide deposits. Clean the oxide deposits

from the igniter electrodes and ame 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 ame sensor if necessary.

Check the igniter electrode spacing gap. Refer to Figure 41 “Igniter Electrode Gap” for details.

Figure 41: Igniter Electrode Gap

5. To gain access to boiler burner and combustion chamber,

rst disconnect and remove gas inlet piping from gas valve. Then, remove six M6X1 hex ange nuts and

take out the burner/blower/gas valve assembly from the boiler.

6. Inspect the assembly for lint and dust presence. If

signicant lint and dust accumulations are found,

disassemble the blower/gas valve assembly to expose

the swirl plate and blower inlet. For parts identication,

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.

9. Inspect the condensate trap to verify it is open and free

from debris. Inspect condensate line integrity between boiler and condensate neutralizer (if used), condensate neutralizer and the drain. Clean/repair if needed.

If the condensate neutralizer is used, check pH before

and after the neutralizer to determine neutralizing effectiveness. Replace limestone chips and clean out the neutralizer if needed.

10. Inspect the ue 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 ange 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

deciencies prior to restarting the boiler.

17. Follow Section IX “System Start-up” before leaving

installation.

18. Perform the combustion test outlined in Section IX

“System Start-up”.

D. Recommended Heating System Water

Treatment Products:

1. System Cleaning and Conditioning:

a. The following heating system water treatment

products are recommended for an initial existing heating system sludge removal, initial boiler

cleaning from copper dust, ux residue and any

boiler debris and for preventive treatment as corrosion/scale inhibitors:

i. Fernox™ Restorer (universal cleaner, sludge

remover, scale remover, ux 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 specic details.

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 specic 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 uid 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 specically 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OverowSwitchandCondensate

Trap Removal and Replacement:

For removal or replacement of the condensate overow

switch and/or condensate trap follow the steps below. For

parts identication, refer to Section XIII “Repair Parts”.

1. CondensateOverowSwitchRemovaland

Replacement:

a. Disconnect power supply to boiler.

b. Remove 2 wire nuts and disconnect overow switch

wire pigtails from boiler wiring.

c. Using pliers, release spring clip securing the

overow 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 overow 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 Overow 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 overow switch

wire pigtails from boiler wiring.

c. Disconnect pressure switch hose from condensate

trap.

d. Disconnect outside condensate compression tting

from condensate trap.

Figure 42: Condensate Overow Switch Orientation

XI. Service and Maintenance (continued)

e. Using pliers, release spring clip securing the

overow 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 overow switch is to

be re-used, follow the appropriate switch removal

steps from Condensate Overow Switch Removal

and Replacement procedure above.

j. Insure that fresh silicon sealant is applied to the

overow 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

Overow 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

°F °C

-20 -28.9 106926

-10 -23.3 80485

0 -17.8 61246

10 -12.2 47092

20 -6.7 36519

30 -1.1 28558

40 4.4 22537

50 10.0 17926

60 15.6 14356

70 21.1 11578

76 24.4 10210

78 25.6 9795

80 26.7 9398

90 32.2 7672

100 37.8 6301

110 43.3 5203

120 48.9 4317

Ohms of

Resistance

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 Ohms of

°F °C

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

Resistance

Supply, Return and Stack Temperature Sensor

Temperature versus Resistance

(12kOhm NTC Sensor), Beta of 3750

Temperature Ohms of

°F °C

32 0 36100

50 10 22790

68 20 14770

77 25 12000

86 30 9810

104 40 6653

122 50 4610

140 60 3250

158 70 2340

176 80 1710

194 90 1270

212 100 950

230 11 0 730

248 120 560

Resistance

100

AHRI APEX Installation, Operating And Service Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual