Burnham Apex Installation and Operation Manual

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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.

103022-04 - 8/13

Price - $5.00

IMPORTANT INFORMATION - READ CAREFULLY

NOTE: The equipment shall be installed in accordance with those installation regulations enforced in the area where the

installation is to be made. These regulations shall be carefully followed in all cases. Authorities having jurisdiction shall be consulted before installations are made.

All wiring on boilers installed in the USA shall be made in accordance with the National Electrical Code and/or local regulations.

All wiring on boilers installed in Canada shall be made in accordance with the Canadian Electrical Code and/or local regulations.

The City of New York requires a Licensed Master Plumber supervise the installation of this product.

The Massachusetts Board of Plumbers and Gas Fitters has approved the Apex™ Series boiler. See the Massachusetts Board of Plumbers and Gas Fitters website, http://license.reg.state.ma.us/pubLic/pl_products/pb_pre_form.asp for the latest Approval Code or ask your local Sales Representative.

The Commonwealth of Massachusetts requires this product to be installed by a Licensed Plumber or Gas Fitter.

The following terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to important information concerning product life.

DANGER

Indicates an imminently hazardous situation which, if not avoided, will result in death, serious injury or substantial property damage.

WARNING

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

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

Indicates special instructions on installation, operation, or maintenance which are important but not related to personal injury hazards.

CAUTION

NOTICE

DANGER

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, NO 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.

WARNING

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.

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 pressure relief valve is installed into the tapping located on left side of appliance. - 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.

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.

Boiler materials of construction, products of combustion and the fuel contain alumina, silica, heavy metals, carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or harmful substances which can cause death or serious injury and which are known to the state of California to cause cancer, birth defects and

other reproductive harm. Always use proper safety clothing, respirators and equipment when servicing

or working nearby the appliance.

Failure to follow all instructions in the proper order can cause personal injury or death. Read all instructions, including all those contained in component manufacturers manuals which are provided with the boiler before installing, starting up, operating, maintaining or servicing.

All cover plates, enclosures and guards must be in place at all times.

NOTICE

This boiler has a limited warranty, a copy of which is printed on the back of this manual. It is the responsibility of the installing contractor to see that all controls are correctly installed and are operating properly when the installation is complete.

TABLE OF CONTENTS

I. Product Description, Specications and Dimensional Data...................... 6

II. Unpacking Boiler........................................................................................ 10

III. Pre-Installation and Boiler Mounting.......................................................... 11

IV. Venting...................................................................................................... 15

A. General Guidelines............................................................................... 15

B. CPVC/PVC Venting.............................................................................. 18

C. Polypropylene Venting......................................................................... 26

D. Stainless Steel Venting........................................................................ 30

E. Concentric Polypropylene Venting....................................................... 32

F. Removing the Existing Boiler............................................................... 38

G. Multiple Boiler Installation Venting....................................................... 40

V. Condensate Disposal................................................................................. 43

VI. Water Piping and Trim............................................................................... 45

VII. Gas Piping ............................................................................................... 59

VIII. Electrical ................................................................................................... 63

IX. System Start-Up ....................................................................................... 75

X. Operation...................................................................................................... 81

A. Overview.............................................................................................. 81

B. Supply Water Temperature Regulation................................................ 82

C. Boiler Protection Features.................................................................... 83

D. Multiple Boiler Control Sequencer........................................................ 84

E. Boiler Sequence of Operation.............................................................. 85

1. Normal Operation........................................................................... 85

2. Using the Display............................................................................ 86

F. Viewing Boiler Status.......................................................................... 87

1. Status Screens............................................................................... 87

2. Detail Screens................................................................................ 88

3. Multiple Boiler Sequencer Screens................................................ 89

G. Changing Adjustable Parameters........................................................ 90

1. Entering Adjust Mode.................................................................... 90

2. Adjusting Parameters.................................................................... 90

XI. Service and Maintenance ........................................................................ 101

XII. Troubleshooting........................................................................................ 105

XIII. Repair Parts ............................................................................................. 109

Appendix A - Figures................................................................................ 124

Appendix B - Tables.................................................................................. 127

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

Table 1: Dimensional Data (See Figures 1A, 1B and 1C)

Dimension

APX399 APX500 APX800

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)

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

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.).

Boiler Model

44-7/8 (1140)

22-1/8

(562)

(737)

39-11/16

(1008) 29-3/8

(752)

54-9/16

(1384)

28-3/8

(724)

34-1/4

(876)

48-1/16

(1226)

33-13/16

(864)

Supply H 1-1/2” (FPT) 2” (MPT)

Condensate Drain J Factory Provided Socket End Compression Pipe Joining Clamp for 3/4” Schedule 40 PVC Pipe

Boiler Two-Pipe

CPVC/PVC Vent Connector

(Figures 1A, 1B and 1C) - Inch

Approx. Shipping Weight (LBS) 304 350 430

4 x 4 6 x 6

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

Figure 1A: Apex™ - Model APX399

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

Figure 1B: Apex™ - Model APX500

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

Figure 1C: Apex™ - Model APX800

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

Table 2A: Rating Data - Models APX399, APX500 and APX800 (0 to 5000 Feet Elevation Above Sea Level)

Apex Series Gas-Fired Boilers

Model

Number

APX399 80 399 375 326 94.1 94.5 3.4 41.8

APX500 100 500 475 413 95.0 95.0 4.2 50.8

APX800 160 800 760 661 95.0 93.0 5.0 65.3

Notes: * Gross Output

Maximum Allowable Working Pressure, Water - 160 PSI Safety Relief Valve Pressure, Water - 50 PSI Shipped from Factory (std.) (APX399 and APX500); 60 PSI Shipped from Factory (std.) (APX800); 80 PSI and 100 PSI - optional (APX399, APX500 and APX800) Maximum Allowable Temperature, Water - 210°F APX399 and APX500 Boiler models are factory shipped as Natural Gas builds and have to be eld adjusted for LP gas application. Refer to ‘System Start- Up Section of this manual for detailed procedure.

APX800 Boiler Model is factory shipped as either Natural Gas build or LP gas build. Ratings shown are for installations at sea level and elevations up to 2000 Feet. For elevations above 2000 Feet,

ratings should be reduced at the rate of two and half percent (2.5%) for each 1000 Feet above sea level.

Input (MBH)

Min. Max.

* Output

(MBH)

Net AHRI

Ratings Water

(MBH)

Thermal

Efciency

(%)

Combustion

Efciency (%)

Boiler Water

Volume (Gal.)

Heat Transfer

Area

(Sq. Ft.)

Table 2B: Rating Data - Models APX399, APX500 and APX800 (5001 to 10000 Feet Elevation Above Sea Level)

Apex Series Gas-Fired Boilers

Model

Number

Input (MBH)

Min. Max.

* Output

(MBH)

Net AHRI

Ratings

Water (MBH)

Thermal

Efciency

(%)

Combustion

Efciency (%)

Boiler Water

Volume

(Gal.)

Heat Transfer

Area

(Sq. Ft.)

APX399 80 399 375 328 94.1 94.5 3.4 41.8

APX500 167 500 475 413 95.0 95.0 4.2 50.8

APX800 267 800 760 661 95.0 93.0 5.0 65.3

Notes: * Gross Output

APX800 Boiler Model is factory shipped as either Natural Gas build or LP gas build. Ratings shown are for installations at sea level and elevations up to 2000 Feet. For elevations above 2000 Feet,

ratings should be reduced at the rate of two and half percent (2.5%) for each 1000 Feet above sea level.

II. Unpacking Boiler

D. Remove boiler from cardboard positioning sleeve on

CAUTION

Do not drop boiler.

A. Move boiler to approximate installed position.

B. Remove all crate fasteners.

C. Lift and remove outside container.

shipping skid.

WARNING

Installation of this boiler should be undertaken only by trained and skilled personnel from a

qualied service agency.

E. Move boiler to its permanent location.

III. Pre-Installation and Boiler Mounting

WARNING

If you do not follow these instructions exactly,

a re or explosion may result causing property

damage or personal injury.

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. Burnham Commercial 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.

A. Installation must conform to the requirements of the

authority having jurisdiction. In the absence of such requirements, installation must conform to the National Fuel Gas Code, NFPA 54/ANSI Z223.1, and/or CAN/ CSA B149.1 Installation Codes.

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 inches from left side, front, top and rear of the boiler. Recommended front clearance may be reduced to the combustible material clearance providing:

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.

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, NFPA 54/ANSI Z223.1, Air for Combustion and Ventilation;

Canada - Natural Gas and Propane Installation Code,

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

WARNING

Adequate combustion and ventilation air must

be provided to assure proper combustion.

F. The boiler should be located so as to minimize the

length of the vent system. The PVC combustion air piping, or the optional concentric vent piping, containing integral combustion air inlet 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.

CAUTION

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.

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 relief valve discharge to cause 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.

4. Boiler Installation:

a. For basement installation provide a solid level

base such as concrete, where oor is not level, or, 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.

III. Pre-Installation and Boiler Mounting G. General (continued)

Boiler Clearances to Combustible (and NonCombustible) Material:

APX399 and APX500 Boiler Models:

These boilers are approved for closet installation with

the following clearances – Top = 1”, Front = 1”, Left Side = 10”, Right Side = 2”, Rear = *6”

APX800 Boiler Model:

This boiler is approved for alcove installation with the

following clearances – Top = 1”, Front = Open, Left Side = 10”, Right Side = 2”, Rear = *6”

* Note:

When boiler is vented vertically, the minimum

clearance from the rear of the jacket is increased to 18” 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

Approved Direct

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 Combustion Air Intake

Available Optional

Two-Pipe Stainless Steel Vent and Galvanized Steel or Air Intake

Available Optional

Concentric Inner Polypropylene Vent and Outer Steel Air Intake

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

combustible or non-combustible walls

Vent System

Boiler Service Clearances – Applicable to all Boiler Models:

Top = 24”, Front = 24”, Left Side = 24”, Right Side =

24”, Rear = 24”

The above Clearances are recommended for Service

Access but may be reduced to the Combustible Material Clearances provided:

1. The boiler front is accessible thru 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

Polypropylene

Vent Pipe

Direction

Vertical or Horizontal

Enclosure

Unenclosed at

all Sides

Vent Pipe

Nominal

Diameter

4” or 6” 1”

80 mm 10 mm

(110 mm)

150 mm

(160 mm)

4” or 6” 1”

100/150 mm

(110/160 mm)

Minimum Clearance to Combustible

Material

1”

0”

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 two (2) Apex (APX) boilers will offer the

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

savings and boiler redundancy, the Apex (APX) boilers may be installed stacked one on the top of the other. Refer to Table 3 “Apex (APX) Boiler Model Stacking Combinations” for details.

Table 3: Apex (APX) Boiler Model Stacking Combinations

Bottom

Boiler Model

APX399

APX500 APX399 or APX500 APX800 APX399, APX500 or APX800

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

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

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

Always position higher input boiler model as

bottom boiler.

b. Each Apex (APX) boiler is factory packaged

with two (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 Attachments Bracket has three 7/32” diameter holes punched in a triangular pattern. See Figure 3 “Stacking Boiler Attachment Bracket Placement”.

c. Apex (APX) boiler left and right side panels

have a series of dimples at panel top and bottom. These dimples are positioning dimples for Stacking Boiler Attachment Bracket mounting screws. Side panel bottom positioning dimples are evenly spaced from boiler front and back, while side panel top positioning dimples follow

specic pattern to compensate for Apex (APX)

boiler model variable depth.

d. Position the upper boiler on the top of the bottom

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.

Top Boiler Model

APX399

• 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 forth

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

No common manifolded venting is permitted.

For side-wall venting individual model vent

terminals must terminate not closer than 12 inches horizontally and three (3) feet 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 inches horizontally. If vertical terminals cannot end in one plane, they must be spaced no closer than three (3) feet horizontally.

Chimney chase concentric venting is permitted

for modules, when stackable, providing concentric vertical (roof) vent terminals, if level with each other, are spaced no closer then 12 inches horizontally.

If vertical vent terminals cannot end in one

plane, they must be spaced no closer then three (3) feet 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

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 interchange vent systems or materials unless otherwise specied.

The use of thermal insulation covering vent pipe and ttings is prohibited.

Do not use a barometric damper, draft hood or vent damper with this boiler.

When using the CPVC/PVC vent option, the use of CPVC is required when venting in vertical or horizontal

chase ways, closets and through wall penetrations. The CPVC vent materials supplied with this boiler do not comply with B149.1.S1-07 and are not ap-

proved 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.

Do not locate vent termination where exposed to prevailing winds. Moisture and ice may form on surface around vent termination. To prevent deterioration, surface must be in good repair (sealed, painted, etc.).

Do not locate air intake vent termination where chlorines, chlorouorocarbons (CFC’s), petroleum

distillates, detergents, volatile vapors or other chemicals are present. Severe boiler corrosion and failure will result.

The use of cellular core PVC (ASTM F891), cellular core CPVC or Radel (polyphenolsulfone) is prohibited. Do not locate vent termination under a deck.

Do not reduce specied diameters of vent and combustion air piping.

When installing vent pipe through chimney, as a chase, no other appliance can be vented into the chimney.

Do not allow low spots in the vent where condensate may pool.

A. General Guidelines

1. Vent system installation must be in accordance with National Fuel Gas Code, NFPA 54/ANSI Z221.3 or 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.

2. The Apex™ is designed to be installed as a Direct Vent (sealed combustion) boiler. The air for combustion is supplied directly to the burner

enclosure from outdoors and ue gases are vented

directly outdoors (through wall or roof).

3. The following combustion air/vent system options are approved for use with the Apex™ boilers (refer to Table 4):

a. 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.

b. Two-Pipe Polypropylene Vent/Combustion Air

System - separate rigid or exible polypropylene

pipe serves to expel products of combustion and separate rigid polypropylene pipe or PVC pipe delivers fresh outdoor combustion air. Refer to

part C for specic details.

c. Two-Pipe Stainless Steel Vent/Combustion Air

System - separate stainless steel pipe serves to expel products of combustion. Separate PVC or galvanized pipe delivers fresh outdoor air. Refer

to Part D for specic details.

d. Concentric Inner Polypropylene Vent

and Outer Steel Combustion Air System

- the assembly consists of inner re resistant

polypropylene vent pipe and outer steel pipe casing. The inner pipe serves as conduit to expel products of combustion, while outdoor fresh combustion air is drawn through the space between the inner and outer pipes. Refer to Part

E for specic details.

4. Horizontal vent pipe must maintain a 1/4" per foot slope down towards the boiler.

5. Horizontal combustion air pipe must maintain a minimum ¼" per foot slope down towards terminal, when possible. If not, slope toward boiler.

6. Do not install venting system components on

the exterior of the building except as specically

required by these instructions (refer to Figure 4):

a. Vent terminals must be at least 1 foot from door,

window, or gravity inlet into the building.

b. Maintain the correct clearance and orientation

between the vent and air intake terminals.

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

Available Optional

Concentric, Inner

Polypropylene Vent and

Outer Steel Air Intake

Vent

Material

CPVC/PVC

Rigid

Polypropylene

(or Flexible

Polypropylene

Liner for vertical

Venting only)

Stainless Steel

Polypropylene

Orientation Termination Description Figures

Standard

(thru sidewall)

Horizontal

Optional

Snorkel

(thru sidewall)

Optional

Vertical

Horizontal

Optional

Vertical

Horizontal

Vertical Vertical (thru roof)

Horizontal

Vertical

(thru roof)

Standard

(thru sidewall)

Optional Snorkel

(thru sidewall)

Vertical

(thru roof or

chimney/chase)

Standard

(thru sidewall)

Optional Snorkel

(thru sidewall)

Horizontal

(Wall) Terminal

Vertical (Roof)

Terminal

The system includes separate CPVC

vent pipe and PVC air intake pipe

terminating thru 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 thru 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 thru 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 thru roof with individual penetrations for the vent

and air intake and individual vent /air terminals.

The system includes separate stainless

steel vent pipe and PVC/galvanized steel

air intake pipe terminating thru 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 thru roof with individual penetrations for the vent and

air intake piping and separate terminals.

Concentric vent/air pipe terminates thru

sidewall.

Concentric vent/air pipe terminates thru

roof.

Component

Table

4 thru 9A,

9B, 10

4 thru 7,

10, 11

4 thru 6, 10,

12, 13

4 thru 9A,

9B, 10

4 thru 7,

10, 11

12 thru 16 9, 10

9A, 9B,

16, 17

11, 16, 17

12, 13, 17

18 thru 25

18 thru 21,

26 thru 31

9, 10

11A, 11B D.

12, 13 E.

Part

i. The centerlines between the vent and air

intake terminals must be spaced a minimum of 12” apart. More than 12” spacing is recommended.

ii. If possible, locate air intake and vent

terminations on the same wall to prevent nuisance shutdowns. However, boiler may be installed with vertical venting and sidewall combustion air inlet or vice versa where installation conditions do not allow for alternate arrangement.

iii. The vent and air intake terminations may

be at varying heights when installed on the same wall, but the height of the vent termination should always be higher than the air intake termination and within the

specied limit as shown in Figure 9B.

c. The bottom of the vent and air intake terminal

must be at least 12" (18" in Canada) above the normal snow line. In no case should they be less than 12" above grade level.

d. The bottom of the vent terminal must be at least

7 feet above a public walkway.

e. Do not install the vent terminal directly over

windows or doors.

f. The bottom of the vent terminal must be at least

3 feet above any forced air inlet located within 10 feet.

g. A clearance of at least 4 feet horizontally must

be maintained between the vent terminal and gas meters, electric meters, regulators, and relief equipment. Do not install vent terminal over this equipment.

IV. Venting A. General Guidelines (continued)

Figure 4: Location of Vent Terminal Relative to Windows, Doors, Grades,

Overhangs, Meters and Forced Air Inlets

(Concentric Terminal Shown - Two-Pipe System Vent Terminal to be installed in same location -

Two-Pipe System Air Intake Terminal Not Shown)

h. Do not locate the vent terminal under decks or

similar structures.

i. Minimum twelve (12) inches vertically from any

roof overhang twelve (12) inches or less wide.

If a roof overhang width exceeds twelve (12)

inches the terminal vertical clearance must be

increased to avoid ue vapor condensation.

j. Top of vent terminal must be at least 5 feet

below eaves, softs, or overhangs. Maximum

depth of overhang is 3 ft.

k. If window and/or air inlet is within four (4) feet

of an inside corner, then terminal must be at least six (6) feet from adjoining wall of inside corner.

l. Concentric - Minimum twelve (12) inches

horizontally from 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 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 air intake

terminals on a wall away from the prevailing

Installing multiple individual module (boiler) vent terminations too close together may result in cross contamination and combustion product water vapor condensation on building surfaces, where

vent termination 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.

wind. Reliable operation of this boiler cannot be guaranteed if the terminal is subjected to winds in excess of 40 mph.

o. Air intake terminal must not terminate in areas

that might contain combustion air contaminates, such as near swimming pools.

p. For sidewall venting the minimum horizontal

distance between any adjacent individual module (boiler) vent terminations is twelve (12) inches.

Increasing this distance is recommended to avoid

frost damage to building surfaces where vent terminations are placed.

CAUTION

IV. Venting A. General Guidelines (continued)

q. The minimum horizontal distance between any

adjacent individual module (boiler) roof vent terminations is one (1) foot.

7. Use noncombustible ¾" 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 four (4) feet. Avoid low spots where condensate may pool. Do not penetrate any part of the vent system with fasteners.

8. Maintain minimum clearance to combustible materials. See Figure 2 for details.

9. Enclose vent passing through occupied or unoccupied spaces above boiler with the material

having a re resistance rating of 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.

10. Multiple individual module vertical vent pipes may be piped through a common conduit or chase so that one roof penetration may be made.

B. CPVC/PVC Venting

WARNING

All CPVC vent components (supplied with boiler) must be used for near-boiler vent piping before transitioning to Schedule 40 PVC pipe (ASTM

2665) components for remainder of vent system.

WARNING

CPVC vent components must be used within any interior space where air cannot circulate freely, such as air inside a stud wall, and in any boiler closet or chase way.

When using the CPVC/PVC vent options, the

use of CPVC is required when venting in vertical

or horizontal chase ways. All condensate that forms in the vent must

be able to drain back to the boiler.

1. Components and Length Restrictions

a. See Table 5A for CPVC/PVC Vent & Air Intake

Components included with boiler, Table 5B for CPVC/PVC Vent and Air Intake Components (Installer Provided) required for Optional

Table 5A: CPVC/PVC Vent & Air Intake Components Included With Boiler

Quantity

Vent & Air Intake Components

4” Schedule 40 PVC Tee (Vent or Air Intake Terminals) 102190-02 2 N/A

6” Schedule 40 PVC 90° Elbow (Vent or Air Intake

Terminal)

4” Stainless Steel Rodent Screen 102191-02 2 N/A

6” Stainless Steel Rodent Screen 102191-03 N/A 2

4” x 30” Schedule 40 CPVC Pipe 102193-02 1 N/A

6” x 30” Schedule 40 CPVC Pipe 103267-01 N/A 1

4” Schedule 80 CPVC 90° Elbow 102192-02 1 N/A

6” Schedule 80 CPVC 90° Elbow 103268-01 N/A 1

4 oz. Bottle of Transition Cement 102195-01 1

4 oz. Bottle of Primer 102194-01 1

4" Vent/4" Combustion Air CPVC/PVC Connector 102183-03 1 N/A

6" Vent/6" Combustion Air CPVC/PVC Connector 103270-01 N/A 1

4" Vent/4" Combustion Air CPVC/PVC Connector

Gasket

6" Vent/6" Combustion Air CPVC/PVC Connector

Gasket

Part

Number

103313-01 N/A 2

102185-02 1 N/A

103248-01 N/A 1

APX399 and APX500

Standard Termination

Vent Kit

(P/N 102189-03)

includes

APX800

Standard Termination

Vent Kit

(P/N 103253-01)

includes

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

Table 5B: CPVC/PVC Vent & Air Intake Components (Installer Provided) required for Optional Horizontal

(Snorkel) Termination

Quantity

Vent Components

4" Schedule 40 PVC Pipe x up to 7 ft. max. vertical run

6" Schedule 40 PVC Pipe x up to 7 ft. max. vertical run N/A 2

4" Schedule 40 PVC 90° Elbow 4 N/A

6" Schedule 40 PVC 90° Elbow N/A 4

4" Schedule 40 PVC Pipe x ½ ft. min. horizontal run 2 N/A

6" Schedule 40 PVC Pipe x ¾ ft. min. horizontal run N/A 2

Part

Number

N/A

Supplied by Others

Table 5C: CPVC/PVC Vent & Air Intake Components (Installer Provided) required for Optional Vertical

(Roof) Termination

Vent Components

4" Schedule 40 PVC Coupler

6" Schedule 40 PVC Coupler N/A 1

4" Schedule 40 PVC 90° Elbow 2 N/A

6" Schedule 40 PVC 90° Elbow N/A 2

4" Schedule 40 CPVC Pipe x ½ ft. min. horizontal run 1 N/A

6" Schedule 40 CPVC Pipe x ¾ ft. min. horizontal run N/A 1

Supplied by Others

Part

Number

N/A

APX399 and APX500

Horizontal (Snorkel)

Termination

2 N/A

APX399 and APX500

Vertical (Roof)

Termination

1 N/A

APX800

Horizontal (Snorkel)

Termination

Quantity

APX800

Vertical (Roof)

Termination

Horizontal (Snorkel) Termination and Table 5C for CPVC/PVC Vent and Air Intake Components (Installer Provided) required for Optional Vertical (Roof) Termination.

b. Vent length restrictions are based on equivalent

length of vent/combustion air pipe (total length of straight pipe plus equivalent length of

ttings). Maximum vent/combustion air lengths

are listed in Table 8. Do not exceed maximum vent/combustion air lengths. Table 6 lists

equivalent lengths for ttings. Do not include

vent/combustion air terminals in equivalent feet calculations. See “Combustion Air/Vent, Equivalent Length Work Sheet”.

c. The vent termination location is restricted as per

'General Guidelines', Paragraph A, 6.

(Refer to Figure 4).

2. System 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. Do not exceed maximum Vent/Combustion Air

length. Refer to Table 8.

c. Design the Vent System to allow 3/8" of thermal

expansion per 10 feet of CPVC/PVC pipe. Runs of 20 feet or longer that are restrained at both ends must use an offset or expansion loop. Refer to Figure 5 and Table 7.

d. Follow all manufacturer instructions and

warnings when preparing pipe ends for joining and using the primer and the cement.

3. Field Installation of CPVC/PVC Two-Pipe

Vent System Connector

Refer to Figure 6 and Steps below:

a. Position the CPVC/PVC vent connector and

gasket onto boiler rear/bottom 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/bottom panel engagement holes; than, secure the connector and gasket to the panel with six mounting screws.

c. Apply supplied dielectric grease (grease pouch

attached to two-pipe vent connector) to gasket inside vent section of two-pipe vent connector, The grease will prevent gasket rupture when inserting vent pipe and gasket deterioration due to condensate exposure.

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

Table 6: Vent System and Combustion Air System Components Equivalent Length

vs. Component Nominal Diameter

Vent or Combustion Air System

Component Description

Equivalent Length (Ft.) for Vent or Combustion Air System Component

vs. Component Nominal Diameter (In.)

Component Nominal Diameter, In. 4” 6”

90° Elbow (Sch. 80 or Sch.40) 13 22

45° Elbow (Sch. 80 or Sch. 40) 4.5 7.5

Sch. 40 CPVC Pipe x 30 In. Long 2.5

Sch. 40 PVC Pipe x 1 Ft. Long 1

Sch. 40 PVC Pipe x 2 Ft. Long 2

Sch. 40 PVC Pipe x 3 Ft. Long 3

Sch. 40 PVC Pipe x 4 Ft. Long 4

Sch. 40 PVC Pipe x 5 Ft. Long 5

LOOP LENGTH

(L)

CHANGE OF DIRECTION

(VERTICAL OR HORIZONTAL)

LONG RUN OF PIPE

OFFSET

L 2

KEY

RESTRAINT (RESTRICTS MOVEMENT)

HANGER (ALLOWS MOVEMENT)

Table 7: Expansion Loop Lengths

Nominal

Pipe

Dia. (In.)

Length of

Straight Run

(Ft.)

20 60

30 74

40 85

50 95

60 104

20 73

30 90

40 103

50 116

60 127

Loop Length

“L” (In.)

LOOP

(HORIZONTAL ONLY)

(TOP VIEW)

MIN

L 5

MIN

Figure 5: Expansion Loop and Offset

L 4

2 L

WARNING

Apply supplied dielectric grease to gasket inside vent section of two-pipe vent connector. Failure to apply the grease could result in gasket rupture during vent pipe installation and gasket deterioration due to condensate exposure.

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

Figure 6: Field Installation of CPVC/PVC Two-Pipe Vent System Connector

4. Near-Boiler Vent/Combustion Air Piping

Refer to Figure 7 and the following Steps:

APX399 and APX500 Boiler Models:

a. 4” x 4” Two-Pipe CPVC/PVC Vent System

Connector (P/N 102183-03), used on APX399 and APX500 boiler models, has factory installed internal sealing gaskets at both vent and air intake sections.

b. Install provided 4” Schedule 40 x 30” long

CPVC pipe into the connector vent section with a slight twisting motion and secure by tightening the metal strap.

c. All CPVC vent components supplied with

boiler inside vent carton (4” Schedule 40 x 30”

long CPVC pipe and 4” Schedule 80 CPVC 90° Elbow) must be used for near-boiler piping before transitioning to Schedule 40 PVC (ASTM

2665) pipe components for reminder of vent system. The CPVC 30” long 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.

d. Insert 4” Schedule 40 PVC combustion air pipe

(installer provided) into the connector air intake section with a slight twisting motion and secure by tightening the metal strap.

Figure 7: Near-Boiler Vent/Combustion Air Piping

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

Table 8: Vent/Combustion Air Pipe Length – Two-Pipe Direct Vent System Options CPVC/PVC Polypropylene (PP) or Polypropylene (PP)/PVC Stainless Steel/PVC or Galvanized Steel)

Boiler

Model

APX399 30 In. 100 Ft. 30 In. 100 Ft.

APX500 30 In. 100 Ft. 30 In. 100 Ft.

APX800 30 In. 200 Ft. 30 In. 200 Ft.

4” Combustion Air Pipe

(Equivalent Length)

Min. Max. Min. Max. Min. Max. Min. Max.

6” Combustion Air Pipe

(Equivalent Length)

4” Vent Pipe

(Equivalent Length)

6” Vent Pipe

(Equivalent Length)

Vent/Combustion Air Equivalent Length Calculation Work Sheet

Combustion Air Vent

90° Elbow(s) PVC (Installer Supplied) 90° Elbow(s) CPVC (Supplied with Boiler)

Nominal

Diameter,

In.

4 13 4 1 13 13 6 22 6 1 22 22

Nominal

Diameter,

In.

4 4.5 4 13 6 7.5 6 22

Nominal

Diameter,

In.

4 1 4 4.5 6 1 6 7.5

* Total Equivalent Length, Ft. (A+B+C) = 30” (2.5 Ft.) Straight Pipe, CPVC (Supplied with Boiler)

* Note: Total Equivalent Length Calculated Value Cannot Exceed Max. Equivalent Length Values shown in Table 8. Vent and Combustion Air Terminals Do Not Count Towards Total Equivalent Length.

Quantity

(Pc)

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

Quantity

(Pc)

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

Quantity

(Length,

Ft.)

Equivalent

Length, Ft/Pc

Equivalent

Length, Ft/Pc

Equivalent

Length,

Ft/Ft

Subtotal,

Equivalent

Ft. (A)

Subtotal,

Equivalent

Ft. (B)

Subtotal,

Equivalent

Ft. (C)

Nominal

Diameter,

In.

Nominal

Diameter,

In.

Nominal

Diameter, In.

Nominal

Diameter,

In.

4 2.5 1 2.5 6 2.5 1 2.5

Nominal

Diameter,

4 1 6 1

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

Quantity

(Pc)

Quantity

(Pc)

Quantity

(Length, Ft.)

Quantity

(Length, Ft.)

Straight Pipe, PVC (Installer Supplied)

Quantity

(Length, Ft.)

Equivalent Length,

Ft/Pc

Equivalent Length,

Ft/Pc

Equivalent Length,

Ft/Ft

Equivalent Length,

Ft/Ft

Equivalent Length,

Ft/Ft

Subtotal,

Equivalent Ft.

(D)

Subtotal,

Equivalent Ft.

(A)

Subtotal,

Equivalent Ft.

(B)

Subtotal,

Equivalent Ft.

(E)

Subtotal,

Equivalent Ft.

(C)

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

e. 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.

APX800 Boiler Model:

f. 6” x 6” Two-Pipe CPVC/PVC Vent System

Connector (P/N 102183-03), used on APX800 boiler model, does not have factory installed internal sealing gaskets at both vent and air intake sections and requires use of supplied red RTV silicon sealant to seal vent and combustion air pipes to the connector.

g. Apply a coating of the sealant, at least 1” wide,

onto provided 6” Schedule 40 x 30” long CPVC pipe.

h. Insert the coated end of the CPVC pipe with a

slight twisting motion into the connector vent section and secure by tightening the metal strap.

i. All CPVC vent components supplied with

boiler inside vent carton (6” Schedule 40 x 30” long CPVC pipe and 6” 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 CPVC 30” long 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.

Figure 8: Wall Penetration Clearances for PVC Vent Pipe

• 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 8 “ Wall Penetration Clearances for PVC Vent Pipe”):

- The wall penetration is at least 66 inches from the boiler as measured along the vent

j. Apply a coating of the sealant, at least 1” wide,

onto 6” Schedule 40 PVC combustion air pipe (installer provided).

k. Insert the coated end of the PVC pipe with a

slight twisting motion into the connector air intake section and secure by tightening the metal strap.

l. 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.

5. Horizontal Vent Termination

a. Standard Two-Pipe Termination

See Figures 8 through 11.

i. Vent Piping

Running PVC vent pipe inside Enclosures

and thru Walls:

Figure 9A: Direct Vent - Sidewall Terminations

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

Figure 9B: Direct Vent - Sidewall Terminations (Optional)

- The wall is 12” thick or less

- An air space of at least of that shown in Figure 8 is maintained around outside of the vent pipe to provide air circulation

• If above three conditions cannot be

met simultaneously when penetrating a combustible wall, use a single wall thimble [Burnham Commercial part numbers 102181-01 (4”) and 103419-01 (6”)].

• 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.

• 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 weathertight seal. Sealant should not restrain the expansion of the vent pipe.

• Install Rodent Screen and Vent Terminal

(supplied with boiler). See Figure 10 for

appropriate conguration details.

WARNING

All CPVC pipe supplied with boiler vent carton must be used as part of vent system prior to connecting supplied PVC vent terminal.

Methods of securing and sealing terminals to the outside wall must not restrain the thermal expansion of the vent pipe.

ii. Combustion Air Piping

• Do not exceed maximum combustion air

pipe length. Refer to Table 8.

• 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

10 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 10 and 11.

This installation will allow a maximum of seven (7)

feet vertical exterior run of the vent/combustion air piping to be installed on the CPVC/PVC horizontal venting application.

Figure 10: Rodent Screen Installation

Figure 11: Direct Vent - Optional Sidewall

Snorkel Terminations

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

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 seven (7)

feet of Schedule 40 PVC vent pipe. See Figure 11.

• 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 10 for

appropriate conguration.

• Brace exterior piping if required.

ii. Combustion Air Piping

• After penetrating wall, install a Schedule

40 PVC 90 the up direction.

• Install maximum vertical run of seven (7)

feet of Schedule 40 PVC vent pipe. See Figure 11.

• 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

10 for appropriate conguration.

• Brace exterior piping if required.

elbow so that elbow leg is in

CAUTION

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 Sealant between vent pipe and storm collar to provide weather-tight seal.

• Install Rodent Screen and Vent Terminal

(supplied with boiler), see Figure 10 for

appropriate conguration.

• Brace exterior piping if required.

WARNING

All CPVC pipe and elbow supplied with boiler vent carton must be used as part of vent system prior to connecting supplied PVC vent terminal.

Do not operate boiler without the rain cap over vent pipe in place.

ii. Combustion Air Piping

• Locate combustion air termination on the

same roof location as the vent termination to prevent nuisance boiler shutdowns. Combustion air terminal can be installed closer to roof than vent.

6. Vertical Vent Termination

a. Standard Two-Pipe Termination Refer to Figures 10, 12 and 13.

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 12 and

13.

- Size roof opening to maintain minimum

clearance of 1" from combustible materials.

- Extend vent pipe to maintain minimum

vertical and horizontal distance of twelve (12) inches from roof surface. Additional vertical distance for expected snow accumulation. Provide brace as required.

Figure 12: Direct Vent - Vertical Terminations

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

Figure 13: Direct Vent - Vertical Terminations

with Sloped Roof

Extend vent/combustion air piping to maintain minimum vertical (‘X’) and minimum horizontal (‘Y’) distance of twelve (12) inches (18 inches Canada) from roof surface. Allow additional vertical (‘X’) distance for expected snow accumulation.

• 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 twelve (12) inches 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 between combustion air pipe and storm collar to provide weather-tight seal.

• Install Rodent Screen and Combustion

Air Terminal (supplied with boiler), see

Figure 10 for appropriate conguration.

• Brace exterior piping if required.

C. Polypropylene Venting

Apex boilers have been approved for use with

polypropylene vent system.

It is an installing contractor responsibility to

procure listed below polypropylene vent system pipe

and related components.

Polypropylene vent system manufactures are listed

below:

Approved Polypropylene Vent System Manufacturers

Make Model

PolyPro Single Wall Rigid Vent

M&G/DuraVent

Centrotherm

Eco Systems

PolyPro Flex Flexible Vent (APX399 and

APX500)

InnoFlue SW Rigid Vent Flex Flexible Vent (APX399 and APX500)

NOTE: Do not mix vent components from approved manufacturers.

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’.

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’.

For polypropylene vent system installation details refer

to an approved manufacturer either Rigid Single Wall Polypropylene Vent Installation Instructions, or Flexible Polypropylene Vent Installation Instructions provided

with a manufacturer specic kits. See Tables 9 and 10.

Refer to Table 8 ‘Vent/Combustion Air Pipe Length –

Two-Pipe Direct Vent System Options’ for minimum and maximum listed equivalent length values.

All terminations must comply with listed options for

two-pipe venting system. See Figures 8 thru 12 for details.

IV. Venting C. Polypropylene Venting (continued)

Table 9: Approved Polypropylene Pipe, Fittings and Terminations - M&G/DuraVent

Boiler Model

APX399

APX500 APX800 6PPS-06PVCM-6PPF 150 mm N/A 6PPS-LBC 6PPS-E90B N/A

Male Boiler Adapter,

PVC to PP

4PPS-04PVCM-4PPF 100 mm 100 mm 43PPS-LB 43PPS-TB 4PPS-FK

Rigid Pipe Flex Pipe

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

Boiler Model

APX399

APX500

APX800

Male Boiler Adapter,

PVC to PP

ISAA0404

ISSAL0404

ISAA0606

ISSAL0606

Rigid Pipe Flex Pipe

110 mm 110 mm IANS04 ISTT0420

160 mm N/A IANS06 ISTT0620 N/A

M&G / DuraVent Part Numbers/Sizes

Pipe Joint

Locking Band

Centrotherm Eco Part Numbers/Sizes

Pipe Joint

Locking Band

Side Wall

Termination Tee

Side Wall

Termination Tee

Chimney Kit for

Venting Only

Chimney Kit for

Venting Only

IFCK0425

and

IFCK0435

When using exible polypropylene vent pipe (liner):

• Flexible pipe must be treated carefully and stored at

temperatures higher than 41°F (5°C).

• 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.

CAUTION

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.

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.

CAUTION

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.

• 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.

• Follow flexible 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 thru masonry chimney for combustion product venting or, combination of combustion product venting and combustion air supply).

• When there is a conflict between flexible polypropylene pipe (liner) manufacturer installation instructions and Apex boiler Installation, Operating and Service Instructions, the more restrictive instructions shall govern.

Apex Boiler Two-Pipe Vent System Connector Field

Modication Procedure To Accept Polypropylene

Vent Piping:

Apex boilers are factory supplied with a model-specic

boiler two-pipe CPVC/PVC vent system connector

shipped within a model-specic boiler CPVC gasketed

vent kit carton.

Locate and remove a model-specic boiler two-pipe

CPVC/PVC vent system connector.

When using M&G/DuraVent polypropylene pipe for

combustion product venting and/or air supply, male PVC to PP boiler adapter (4PPS-04PVCM-4PPF or 6PPS-06PVCM-6PPF as applicable) is installed into the two-pipe vent system connector vent or combustion air supply port as follows (see Figure 14):

1) APX399 and APX500 models - Apply provided dielectric grease (grease pouch taped to the vent system connector) all around to the vent or air connection inner red silicon gasket.

2) APX399 and APX500 models - Push and twist PVC to PP boiler adapter (4PPS-04PVCM-4PPF) into two-pipe vent system connector vent connection or air supply port until bottomed out.

IV. Venting C. Polypropylene Venting (continued)

Figure 14: Vent System Field Modication to Install PVC to PP Adapter (M&G/DuraVent Shown)

3) Tighten the worm band clamp screw to secure PVC to PP boiler adapter.

4) Do not install PVC to PP boiler 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.

5) APX800 model - Apply a coating of supplied red RTV silicon sealant, at least 1” wide, to PVC to PP boiler adapter (6PPS-06PVCM-6PPF) male end,

when used for combustion product venting.

If polypropylene pipe is also used for combustion air

supply, application of the silicon sealant to PVC to PP boiler adapter (6PPS-06PVCM-6PPF) male end is not required.

6) APX800 model - Push and twist PVC to PP boiler adapter (6PPS-06PVCM-6PPF) into two-pipe vent system connector vent port or air supply port until bottomed out.

7) Tighten the worm band clamp screw to secure PVC to PP boiler adapter.

8) Do not install PVC to PP boiler 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.

When using Centrotherm Eco polypropylene pipe

for combustion product venting and/or air supply PVC to PP boiler adapter (ISAA0404 or ISAAL0404 and ISAA0606 or ISAAL0606 as applicable) is installed into the two-pipe vent system connector vent or combustion air supply port as follows (see Figure 14):

9) APX399 and APX500 models - Apply provided dielectric grease (grease pouch taped to the vent system connector) all around to the vent or air connection inner red silicon gasket.

10) APX399 and APX500 models - Push and twist PVC to PP boiler adapter (ISAA0404 or ISAAL0404) into two-pipe vent system connector vent connection or air supply port until bottomed out.

11) Tighten the worm band clamp screw to secure PVC to PP boiler adapter.

12) Do not install PVC to PP boiler 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.

13) APX800 model - Apply a coating of supplied red RTV silicon sealant, at least 1” wide, to PVC to PP boiler adapter (ISAA0606 or ISAAL0606) male end, when used for combustion product venting.

If polypropylene pipe is also used for combustion air

supply, application of the silicon sealant to PVC to PP boiler adapter (ISAA0606 or ISAAL0606) male end is not required.

14) APX800 model - Push and twist PVC to PP boiler adapter (ISAA0606 or ISAAL0606) into two-pipe vent system connector vent port or air supply port until bottomed out.

15) Tighten the worm band clamp screw to secure PVC to PP boiler adapter.

16) Do not install PVC to PP boiler 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.

Optional Two-pipe Vertical Venting Installation –

Running Flexible Polypropylene Vent (Liner)

Thru Unused Chimney Chase (see Figure 15).

Apex APX399 and APX500 boilers are approved for

vertical venting by installing Flexible Vent in an UNUSED masonry chimney/chase and supplying combustion air thru a separate wall or roof air intake terminal.

IV. Venting C. Polypropylene Venting (continued)

Venting of Other Appliances (or Fireplace) into Chase or Adjacent Flues Prohibited!

Figure 15: Flexible Vent in Masonry

Chimney with Separate Air Intake

WARNING

Follow installation instructions included by the original polypropylene venting component manufacturers, M&G/DuraVent or Centrotherm, whichever applicable.

Flexible Polypropylene Vent must be installed 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 thru any of adjacent ues.

Observe all precautions outlined in either M&G/DuraVent or Centrotherm instructions in addition to those outlined in these instructions.

Examine all components for possible shipping damage prior to installation. Proper joint assembly is essential for safe installation. 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.

Do not mix vent components or joining methods for different vent systems.

Where a conict arises between M&G/DuraVent or Centrotherm instructions and these instructions, the

more restrictive instructions shall govern.

Do not apply thermal insulation to vent pipe and ttings.

Do not obtain combustion air from within the building.

IV. Venting D. Stainless Steel Venting (continued)

D. Stainless Steel Venting

CAUTION

Vent systems made by Heat Fab, Protech and Z-Flex rely on gaskets or 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 in structions. When pipe is cut, cut end must

be square and carefully de-burred prior to

assembly.

WARNING

All condensate that forms in the vent must be able to drain back to the boiler.

Vent Length Restrictions

a. Vent length restrictions are based on equivalent

length of vent/combustion air pipe (total length of straight pipe plus equivalent length of

ttings). Maximum vent/combustion air lengths

are listed in Table 8. Do not exceed maximum vent/combustion air lengths. Do not include vent/combustion air terminals in equivalent feet calculations. See “Combustion Air/Vent, Equivalent Length Work Sheet”.

b. The vent termination location is restricted as

per ‘General Guidelines’, Section A.5. (Refer to Figure 4)

c. Where the use of “silicone” is called for in the

following instructions, use GE RTV 106 or equivalent for the vent collar. Air inlet piping sections are sealed with any general-purpose silicone sealant such as GE RTV102. PVC air inlet piping sections are connected with PVC cement.

d. Longitudinal welded seams should not be placed

at the bottom of horizontal sections of exhaust pipe.

e. Do not drill holes in vent pipe.

f. Do not attempt to mix vent components of

different vent system manufacturers.

2. Near Boiler Connection

To install the stainless steel vent adapter

[P/N 102220-01 (4”)]:

a. Push the stainless steel vent adapter onto the

CPVC/PVC connector with a slight twisting motion. Make sure that the stainless steel vent adapter is inserted at least 1” (refer to Figure 16).

b. Secure the adapter to the CPVC/PVC connector

by tightening the metal strap.

To install the stainless steel vent adapter [P/N 103285-01 (6”)]:

c. Apply a coating of supplied red RTV silicone

sealant, at least 1” wide, all around male end of the stainless steel vent adapter.

d. Afterwards, insert the male end of the adapter

with a slight twisting motion into vent section of installed two-pipe CPVC/PVC vent connector.

e. Secure the adapter to the two-pipe CPVC/PVC

vent connector by tightening the metal strap.

System 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. Refer to Tables 11A and 11B for approved

AL29C Vent Systems.

c. Do not exceed maximum Vent/Combustion air

length. Refer to Table 8.

d. Follow all manufacturer instructions and

warnings when preparing pipe ends for joining and using the primer and the cement.

e. Assemble the air intake system using either

galvanized or PVC pipe.

i. If PVC piping is used, use PVC cement

to assemble the PVC intake system components. See Part B for air intake installation instructions.

ii. If galvanized piping is used, use at least two

sheet metal screws per joint. Seal the outside of all joints.

Horizontal Vent Termination

a. Standard Two-Pipe Termination Refer to Figure 9A.

i. Vent Termination

• Use Burnham Commercial stainless

exhaust terminal [P/N 100184-01 (4”)]. The outer edge of this terminal must be between 6” and 12” from the surface of the wall. The joint between the

terminal and the last piece of pipe must be outside of the building.

• Male end of terminal will t into the

female end of any of the approved stainless vent systems.

IV. Venting D. Stainless Steel Venting (continued)

Figure 16: Field Installation of Two-Pipe Vent

System Adapter for Stainless Steel

• 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

• Horizontal intake terminal is a tee in the

upright position. Tee should protrude the same distance from the wall as the exhaust terminal. See Figure 9A.

• Install a rodent screen (not supplied) in

the inlet terminal. Use a screen having 1/2” x 1/2” mesh.

b. Optional Two-Pipe Snorkel Termination Refer to Figure 11.

This installation will allow a maximum of

seven (7) feet 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 seven (7)

feet of appropriate manufacturer’s vent pipe. See Figure 11.

• 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.

Table 11A: Burnham Commercial Vent System Components (Stainless Steel)

Part Numbers

Vent System

Component

SS Vent Kit 102501-02

Horizontal Vent Terminal (Included in Kit)

PVC to SS Vent Adapter (Included In Kit)

Vertical Vent Terminal 102680-02 Pipe x 1 Ft. 100176-01 1 Pipe x 3 Ft. 100177-01 3 Pipe x 5 Ft. 100178-01 5

Pipe x Adjustable 100179-01

90° Elbow 100180-01 8.0 (4")

45° Elbow 100181-01 4.5 (4")

Horizontal Drain Tee 100182-01 2 Vertical Drain Tee 100183-01 7½ Single Wall Thimble 100184-01 N/A

APX399

and

APX500

4" Vent 6” Vent

8116313

102220-01

APX800

N/A

Equivalent

Feet of Pipe

N/A

Equal to Installed

Length

(1.06 to 1.64)

Table 11B: Alternate Vent Systems and Vent Components (Stainless Steel)

Manufacturer

Protech Systems Inc.. FasNseal

Z-Flex

Flex-L Intl. Star-34

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”)

Size Wall Thimbles Horizontal Termination

4 FSWT4 Tee: FSTT4 FSBS4

6 FSWT6 Tee: FSTT6 FSBS6

4 2SVSWTEF04 Tee: 2SVSTTF04 24SVSTPF04

6 N/A N/A N/A

4 SR04WT15 Tee: SRTT-04 SRTP-04

6 N/A N/A N/A

Termination

Vertical

IV. Venting D. Stainless Steel 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 seven (7)

feet of combustion air pipe. See Figure

11.

• At top of vent pipe length install another

90° elbow os 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.

Vertical Vent Termination

a. Standard Two-Pipe Termination Refer to Figures 12 and 13.

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 an 180° bend (comprised of two (2) 90° elbows) as shown in Figure 12.

• Install rodent screen (not supplied) in the

combustion air terminal. Use a screen having 1/2” (2 x 2) or larger mesh.

E. Concentric Polypropylene Venting

1. Vent Length Restrictions

a. Vent length restrictions are based on equivalent

length of vent pipe i.e. total length of straight

pipe plus equivalent length of ttings. See Table 12 for specied vent length details. Do

not exceed maximum vent length. Table 13 lists available concentric vent components and

includes equivalent vent length for ttings.

b. The vent termination location is restricted as per

‘General Guidelines’, Paragraph A, 5 (refer to Figure 4).

Field Installation of Boiler Concentric Vent

Collar

a. Locate and remove six mounting screws from the

Miscellaneous Parts Carton.

b. Position the Collar onto jacket combination rear/

bottom panel and insert collar inner stainless steel vent pipe into the heat exchanger vent outlet.

Table 12: Concentric Vent Length

Boiler Model

APX399 100/150 mm 32 in.

APX500 100/150 mm 32 in

APX800 N/A N/A N/A N/A

* with optional concentric vent components, see Table 13 for details.

Inner/Outer

Pipe Dia., mm

Vent Length

(Equiv. Ft.)

Minimum * Maximum

60 6-1/2 in

Wall Opening

Diameter

Table 13: Concentric Vent Components (Applicable to APX399 and APX500 only)

Component

Part Number Component Description Size

101548-01 90° Elbow – Long Radius 100/150 mm 8.0 101549-01 45° Elbow - Long Radius 100/150 mm 3.0 101550-01 1 Cut -To-Length Extension, 500 mm (19-1/2”) 100/150 mm 1.63 ** Can be cut 101551-01 Cut -To-Length Extension, 1000 mm (39”) 100/150 mm 3.25 ** Can be cut 101553-01 Fixed Extension, 2000 mm (78”) 100/150 mm 6.5 *** Must not be cut 101809-01 Horizontal (Wall) Terminal 100/150 mm * NA Supplied with boiler 101557-01 Vertical (Roof) Terminal 100/150 mm * NA See Note 1 101558-01 Flat Roof Flashing 100/150 mm 101559-01 Sloped Roof Flashing 100/150 mm See Note 2 101560-01 Support Elbow with Chimney Chase Bracket 100/150 mm 10.0 See Note 3 101561-01 Hanger Wall Bracket 100/150 mm

Notes:

* NA – do not include vent terminal into total vent length calculations. ** These sections have plain male end and beaded female end. See Figure 18 for details. *** These sections have beaded male end and beaded female end. See Figure 19 for details.

1. Vertical terminal can be used with either of the roof ashings listed beneath it.

2. Sloped roof ashing suitable for roof angles between 25° and 45°.

3. Used at base of vertical run inside unused masonry chimney.

Equivalent Vent

Length, Ft

Comments

IV. Venting E. Concentric Polypropylene Venting (continued)

Figure 17: Field Installation of Boiler

Concentric Vent Collar

c. Align collar plate clearance holes with rear/

bottom panel engagement holes; then secure the collar to rear/bottom panel with six mounting screws. See Figure 17.

d. Flue temperature sensor, factory attached to the

boiler wiring harness, is secured to the left boiler jacket panel with tape.

e. Remove the tape and push the sensor rubber plug

into Concentric Vent Collar sensor port until the plug is securely engaged. See Figure 17.

The installation of the Concentric Vent Collar is now

completed.

3. System 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. Do not exceed maximum Concentric vent length.

Refer to Table 12.

c. If additional concentric vent piping is needed:

i. Concentric Vent Cut-To-Length Extension

pipes, identied in Table 13 CAN BE CUT to required length when used as an extension. These pipes have plain male

end and beaded female end. Always cut the pipe from plain male end. See Figure

18 ‘Cut-To-Length Extension (Cuttable)”.

Figure 18: Cut-To-Length Extension (Cuttable)

ii. The remaining Concentric Vent Fixed

Extensions shown in Table 13 CANNOT BE CUT. These pipes have beaded male and beaded female ends. See Figure 19 “Fixed Extension (Non-Cuttable)’.

Figure 19: Fixed Extension (Non-Cuttable)

d. To cut the Concentric Vent Straight pipe to

required length refer to Figure 20 “Cutting Straight Pipe” and the following procedure:

i. Determine the required length of the outer

pipe. When doing this allow an additional 1” of length for insertion into the female end of the adjoining pipe. Mark the cut line on the outer pipe.

ii. Remove the plastic inner pipe by pulling it

out from the female end.

iii. Cut the OUTER PIPE ONLY at the point

marked in Step (a) using aviation shears, a hacksaw, or an abrasive wheel cutter. Be careful to cut the pipe square. De-burr the

cut end with a le or emery cloth.

iv. Make an insertion mark 1” from the male

end of the outer pipe.

v. Cut the plastic inner pipe so that it will

protrude 3/8” beyond the male end of the outer pipe when reinstalled in the outer pipe.

Use a ne tooth hacksaw or a PVC saw to

cut the plastic pipe and be careful to cut the

IV. Venting E. Concentric Polypropylene Venting (continued)

Figure 20: Cutting Straight Pipe

pipe square. De-burr the cut edge of the

plastic pipe with a le, razor blade or ne

sandpaper.

vi. Reinstall the inner pipe.

e. To join Concentric Vent Pipe refer to Figure 21

“Joining Cuttable Pipe” and Figure 22 “Joining Non-Cuttable Pipe” and follow the procedure below:

i. Start assembly of the vent system at the

boiler. Lubricate the brown gasket in the boiler vent collar with a few drops of water.

ii. Push the male end of the rst tting into the

boiler collar until it bottoms out. The male end of cuttable sections should go 1” into the collar until the insertion mark (made in

Step 4 above) is covered. On other ttings,

the bead on the male pipe will be bottom out on the collar (see Figure 22).

iii. The male end of cuttable ttings must be

held to the collar with three (3) #10 x 1/2” sheet metal screws. Drill a 1/8 hole through both outer pipes to start this screw. Use a

drill stop or other means to ensure that the drill bit does not penetrate more than

3/8” into the outer pipe. Do not use a sheet metal screw longer than 1/2” (see

Figure 21).

iv. Use locking bands (provided with all

ttings) to secure non-cuttable pipe, as well as ttings, to the boiler collar (see Figure

22).

Figure 21: Joining Cuttable Pipe

Figure 22: Joining Non-Cuttable Pipe

IV. Venting E. Concentric Polypropylene Venting (continued)

iii. For horizontal (sidewall) installation, the

Horizontal (Wall) Terminal will extend past outer wall surface by 5½” (100/150 mm). See Figure 23 “Horizontal Concentric Venting”.

iv. Install the Horizontal (Wall) Terminal:

• Cut a 6½” (for 100/150 mm) at the

planned location of the horizontal terminal.

• Measure dimension “L” from exterior

wall outer surface to the end of the last

tting. See Figure 24 ‘Dimension “L”’.

Figure 23: Horizontal Concentric Venting

v. Use the same method to join all remaining

vent components except for the terminal.

4. Horizontal Vent Termination

a. Standard Concentric Termination Refer to Figure 23.

i. Permitted terminals for horizontal venting:

Horizontal (Wall) Terminal, [100/150 mm

(P/N 101809-01)] - see Table 13.

ii. Concentric Vent components supplied with

the boiler are packed inside boiler carton and include the following:

• Horizontal (Wall) Terminal,

• Horizontal (Wall) Terminal consists

of Straight section having plain male end with locking band clamp installed; Terminal Assembly with offset vent termination, and Outside Wall Plate, both riveted on the opposite end; overall length is approximately 28-1/8”.

• Separate Inside Wall Plate

• Two Hardware Bags (each bag contains

four screws and four anchors) to attach vent terminal Outside Wall Plate to exterior wall and Inside Wall Plate to interior wall.

Figure 24: Dimension “L”

• When factory Horizontal (Wall)

Terminal needs to be shortened, measure dimension “L” plus 1¼” from inside of the attached Outside Wall Plate and mark the Horizontal (Wall) Terminal outer pipe. To achieve a square cut of the outer pipe, place several marks around the outer pipe to establish a cut line. See Figure 25 ‘ Cutting Vent Terminal Pipe’.

• Carefully cut the outer pipe at the marked

line using aviation shears, a hacksaw etc. Ensure the pipe is cut square and cut end is de-burred.

• Mark the end of the Horizontal (Wall)

Terminal inner polypropylene vent pipe to extend 3/8” past the cut end of the outer pipe. To achieve a square cut of the inner pipe, place several marks around the inner pipe to establish a cut line.

• Cut off the marked end of inner polypropylene vent pipe with a ne tooth

blade hacksaw etc. and de-burr. See Figure 25 “Cutting Vent Terminal Pipe.

This pipe can be removed from the

terminal to ease cutting, if desired.

IV. Venting E. Concentric Polypropylene Venting (continued)

Figure 25: Cutting Vent Terminal Pipe

CAUTION

Exterior wall surface must be reasonably at to

attach the Outside Wall Plate. When exterior wall

surface is not at (covered with vinyl or wood

shingle siding etc.) the siding must be removed,

and a at surface build up ash or above siding

exterior surface to secure/seal the terminal Outside Wall Plate.

•. Install the supplied Inside Wall Plate onto the shortened Horizontal (Wall) Terminal interior end and move the plate to cover interior wall cut opening. Secure the plate with provided fasteners, then, apply the sealant around plate sides to seal it to interior wall (refer to Figure 26).

• Lubricate the brown gasket inside boiler

concentric vent collar or the last section of the vent pipe with small amount of water.

• Ensure that inner pipe of the terminal

is evenly engaged into the gasket all around, then push the termination male end inside boiler concentric vent collar or the last section of the vent pipe, until the

mark (see Step v) is no longer visible.

• Re-install locking band clamp onto the

joint to secure the terminal to the collar or the last section of the vent pipe.

Vertical Vent Termination

a. Standard Concentric Termination Refer to Figures 27 thru 31.

i. In addition to the vertical terminal, either a

Flat Roof Flashing or Sloped Roof Flashing is required for this installation. Refer to Table 12 ‘Concentric Vent Components’ for details.

• Determine the centerline of the terminal location on the roof. For at roof, cut

6½” (100/150 mm) for the terminal. For sloped roof, cut a hole in the roof large enough for the terminal to pass through the roof while remaining plumb.

CAUTION

If the boiler is located directly under the hole, cover it while cutting the hole to prevent debris from falling onto boiler.

IV. Venting E. Concentric Polypropylene Venting (continued)

Figure 26: Completing Horizontal (Wall Terminal Installation)

Figure 27: Vertical Concentric Vent Installation

Figure 28: Dimension "H"

IV. Venting E. Concentric Polypropylene Venting (continued)

• Install the roof ashing using standard practice on the roong system of the

structure.

• If not already done, assemble the venting

system inside the building. The last section of pipe needs to be on the same center line as the terminal and within

19-1/4” of the top edge of the roof

ashing.

• Measure distance “H” from the top edge

of the storm collar to the end of the last

tting as shown in Figure 28.

• Add 1” to distance “H”. Carefully mark

this length on the pipe as shown in Figure

29.

• Cut the outer pipe only at the point marked in Step (e) using aviation shears, a hacksaw, or an abrasive wheel cutter. Be careful to cut the pipe square. De-burr

the cut end with a le or emery cloth.

• Place a mark on the plastic inner pipe

3/8” beyond the end of the outer pipe

(Figure 29). Use a ne tooth hacksaw to

cut the plastic pipe and be careful to cut the pipe square. De-burr the cut edge of

the plastic pipe with a le or emery cloth.

• Make a mark on the terminal section

1” from the cut end of the outer pipe as shown in Figure 29.

Figure 29: Cutting Vertical Terminal

• Slip the terminal section through the

roof from the outside. Push into the last section of vent pipe until the mark made in Step (h) is not longer visible. Secure the terminal to the last piece of pipe with three #10 x 1/2” sheet metal screws. Drill a 1/8” hole through both outer pipes to start these screws. Use a drill stop or

other means to ensure that the drill

bit does not penetrate more than 3/8”

into the outer pipe. Do not use a sheet

metal screw longer than 1/2”.

• Secure the terminal section to the inside

of the roof structure using the mounting bracket provided with the terminal (Figure 30).

Figure 30: Completing Vertical Terminal Installation

F. Removing the Existing Boiler

For installations not involving the replacement of an

b. Optional Concentric Chimney Chase Installation Refer to Figure 31.

i. A vertical concentric vent system can be

installed in an UNUSED masonry chimney.

• The Chimney chase Support Elbow

with attached Mounting Bracket is used at the base of the chimney. Refer to Table 12 ‘Concentric Vent Components’ for details. Slip the elbow over the M10 x 35 screw in the support bracket. Determine the desired vertical location of the support elbow in the chimney and mark the location of the pin, positioned on the back of the support bracket, onto the chimney rear wall. Drill a 7/16” diameter x 3-1/2” deep hole in the marked location, then, insert the back bracket pin into the hole. The front of the elbow mounting bracket should be supported either by bottom of the opening into chimney or installer supplied spacer.

• Construct a weather-tight at roof to

cover the top of the old chimney. Install the vertical terminal through this roof

using the at roof ashing.

existing boiler, proceed to Step B.

IV. Venting F. Removing the Existing Boiler (continued)

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 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 ve (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, NFPA 54/ANSI Z223.1. 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, NFPA 54/ ANSI Z223.1.

Figure 31: Chimney Chase Installation

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

G. Multiple Boiler Installation Venting

1. CPVC/PVC or Polypropylene Venting

a. Multiple Boiler CPVC/PVC or polypropylene

direct venting is shown in Figure 32.

b. Each individual module (boiler) must have own

vent pipe and vent terminal. Refer to Paragraphs B thru E (as applicable) for individual module (boiler) venting guidelines and options.

WARNING

No common manifolded venting (vent piping and vent terminals) is permitted.

c. The individual module (boiler) maximum vent

length - see Table 8.

d. For sidewall venting the minimum horizontal

distance between any adjacent individual module (boiler) vent terminations is twelve (12) inches.

Additional horizontal spacing between any adjacent

individual module (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.

CAUTION

Installing multiple individual module (boiler) vent terminations too close together may result in combustion product water vapor condensation on building surfaces, where vent termination 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 module (boiler) sidewall vent

terminals must be placed at least twelve (12) inches above the ground plus the expected snow accumulation.

f. Multiple individual module vertical vent pipes

may be piped through a common conduit or chase so that one roof penetration may be made.

The minimum horizontal distance between any

adjacent individual module (boiler) roof vent terminations is one (1) foot.

2. PVC Pipe Air Intake Piping

a. Multiple Boiler PVC air intake piping is shown

in Figure 32.

b. Each individual module (boiler) must have own

combustion air intake pipe and combustion air intake terminal. Refer to Paragraphs B thru E (as applicable) for individual module (boiler) combustion air intake guidelines and options.

c. The individual module (boiler) maximum

combustion air intake pipe length - see Table 8.

d. If possible, locate each individual module

(boiler) both combustion air intake termination and vent termination on the same sidewall, to prevent nuisance boiler shutdowns.

However, if same sidewall placement is

problematic, an individual module (boiler) may be installed using vertical venting and sidewall combustion air intake termination (or, vice versa)

3. Concentric Combination Venting/Combustion

Air Intake Piping

a. Concentric Combustion Venting and air intake is

shown in Figure 33.

b. Each individual module (boiler) must have

own concentric vent pipe and vent termination. Follow Section IV “Venting” of this manual for individual module (boiler) concentric venting guidelines.

WARNING

No common manifolded concentric venting is permitted.

c. The individual module (boiler) maximum

concentric vent length - see Table 8.

d. For sidewall venting any adjacent individual

module (boiler) concentric vent terminals must be spaced no closer than 12 inches horizontally and three (3) feet vertically from each other to prevent combustion air contamination.

Additional horizontal spacing between any

adjacent individual module (boiler) concentric vent terminations and increased distance from building surfaces to concentric vent termination end are recommended to avoid frost damage to building surfaces where vent terminations are placed.

e. Individual module (boiler) sidewall concentric

vent terminals must be placed at least twelve (12) inches above the ground plus the expected snow accumulation.

f. For vertical through the roof venting any

adjacent individual module (boiler) vertical vent terminals, if level with each other, must be spaced no closer than 12 inches horizontally.

If vertical vent terminals cannot end in one

plane, they must be spaced no closer than three (3) feet horizontally.

g. Chimney chase concentric venting is permitted

for modules, when stackable, providing concentric vertical (roof) vent terminals, if level with each other, are spaced no closer then 12 inches horizontally.

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

Figure 32: Multiple Boiler Direct Vent Termination

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

Figure 33: Multiple Boiler Concentric Vent Termination

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

If vertical vent terminals cannot end in one

plane, they must be spaced no closer then three (3) feet horizontally.

h. When individual modules (boilers) are installed

in the same horizontal plane, chimney chase vertical concentric venting is permitted provided:

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 stub is located at boiler left side, below inlet and outlet water pipe connections. Refer to Figures 1A and 1B.

i. Sufcient inside space available at the base

of the chimney to install multiple chimney chase brackets and support elbows.

ii. Spacing between adjacent vertical vent

terminals is in accordance with Item ‘g’ above.

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 (8 uid ounces) through condensate trap stub opening. Do not overll the trap.

6. If any additional condensate drain line is needed, construct the extension from PVC or CPVC Schedule 40 pipe. The factory supplied ¾” x 5-5/8” long PVC coupling, located in the Part Carton, must be used to connect drain line to the condensate trap stub. Do not over tighten coupling compression nuts when connecting drain line and condensate trap stub.

WARNING

Failure to install the condensate trap and condensate drain in accordance with the above

instructions could cause ue gas to enter the

building, resulting in personal injury or death.

CAUTION

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.

NOTICE

Use materials approved by the authority having jurisdiction.

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.

V. Condensate Disposal (continued)

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.

Figure 34: Condensate Trap and Drain Line

VI. Water Piping and Trim

WARNING

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. Burnham Commercial’s 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.

A. Installation of Factory Supplied Piping and Trim

Components

Apex (APX) boilers have factory supplied

Miscellaneous Part Carton (P/N 102942-04 – APX399 & APX500; P/N 103259-01 – APX800), which includes supply piping components, gas piping components, Temperature & Pressure Gauge, Pressure Relief Valve and Drain Valve. See Figure 35 “Factory Supplied Piping and Trim Installation”.

Install these components prior to connecting boiler to

system piping as follows:

1. APX399 and APX500 Boiler Models

a. Locate and remove (1) ¾” NPT x close black

nipple, (1) ¾” NPT x 12” black nipple, ¾” NPT black tee, ¾” FPT x ¾” FPT Pressure Relief Valve, ¾” NPT Drain Valve.

b. Install close nipple into tee branch, then, screw

the assembly into boiler left side front ¾” FPT tapping making sure tee run outlets are in vertical plane and parallel to boiler side.

c. Install the ¾” NPT x 12” black nipple into tee

run top outlet.

d. Mount ¾” FPT x ¾” FPT Pressure Relief Valve

onto 12” nipple.

e. Install Drain Valve into the tee bottom outlet.

Figure 35: Factory Supplied Piping and Trim Installation

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

Pressure Drop vs. Flow

f. Locate and remove 1½” NPT x 2” long black

nipple, 1½” x 1½” x ¾” NPT black tee, ¾” x ¼” NPT black reducing bushing and Temperature & Pressure Gauge.

g. Mount the nipple into 1½” FPT boiler supply

tapping (see Figures 1A and 1B), then, install the tee onto the nipple, making sure ¾” branch outlet is in horizontal plane and facing the boiler front.

h. Install ¾” x ¼” NPT black reducing bushing

into the tee branch, then, put in Temperature & Pressure Gauge.

2. APX800 Boiler Model

a. Locate and remove (1) ¾” NPT x close black

nipple, (1) ¾” NPT x 12” black nipple, ¾” NPT black tee, ¾” FPT x 1” FPT Pressure Relief Valve, ¾” NPT Drain Valve.

Table 14: Flow Range Requirement Through Boiler

Boiler

Model

Boiler

Supply

Connection,

Inch, FPT

Boiler

Return

Connection,

Inch, FPT

Minimum

Required

Flow (GPM)

@ 35°F DT

Boiler

Head Loss,

Ft.

@ 35°F DT

@ 30°F DT

Required

Flow,

(GPM)

b. Install close nipple into tee branch, then, screw

the assembly into boiler left side front ¾” tapping making sure tee run outlets are in vertical plane and parallel to boiler side.

c. Install the ¾” NPT x 12” black nipple into tee

run top outlet.

d. Mount ¾” FPT x 1” FPT Pressure Relief Valve

onto 12” nipple.

e. Install Drain Valve into the tee bottom outlet.

f. Locate and remove 2” NPT steel coupling, 2”

NPT x 2-1/2” long black nipple, 2” x 2” x ¾” NPT black tee, ¾” x ¼” NPT black reducing bushing and Temperature & Pressure Gauge.

g. Mount 2” NPT coupling onto 2” MPT boiler

supply stub (see Figure 1C), then, install 2” NPT x 2-1/2” long black nipple into the coupling

Boiler

Head Loss,

Ft.

@ 30°F DT

Required

Flow,

(GPM)

@ 25°F DT

Boiler Head Loss, Ft. @

25°F DT

Maximum

Required

Flow (GPM)

@ 20°F DT

Boiler Head

Loss, Ft.

@ 20°F DT

APX399 1½ 1½ 21.5 6.1 25.1 7.9 30.2 10.8 37.7 15.9

APX500 1½ 1½ 27.1 6.9 31.7 8.9 38.0 12.1 47.5 17.6

APX800 2 2 43.4 12.1 50.7 15.5 60.8 20.9 76.0 30.0

Notes: Required Flow (GPM) = ** Output (MBH) * 1000/500 * DT

** Output (MBH) - Select Value for specic Boiler Model from Table 2A or 2B

Using boiler antifreeze will result in higher uid density and may require larger circulators.

800

500

399

Pressure Drop (Feet o f Head)

0 10 20 30 40 50 60 70 80

Flow Rate (GPM)

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

outlet, then, attach 2” x 2” x ¾” tee onto the nipple opposite end, making sure ¾” branch outlet is in horizontal plane and facing the boiler front.

h. Install ¾” x ¼” NPT black reducing bushing

into the tee branch, then, put in Temperature & Pressure Gauge.

B. Piping System To Be Employed.

Apex (APX) boilers are designed to operate in a closed

loop pressurized system. Minimum pressure in the boiler must be 12 PSI. Proper operation of the Apex

(APX) boiler requires that the water ow through the

boiler remain within the limits shown in Table 14, 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 APX 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 factory recommended and installer supplied boiler circulator.

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 Table 15 and

Figure 36 “Near Boiler Piping - Heating Only” as applicable.

ii. Space heating plus indirect water

heater(s) - refer to Table 15 and Figure 37

“Near Boiler Piping - Heating Plus Indirect Water Heater” as applicable.

NOTICE

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 DT does not exceed 35°F.

2. Direct connection of Apex (APX) 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 14.

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.

Table 15: Recommended Circulator Models for Apex (APX) Boilers Based on 25°F Temperature Differential

and Up to 75 ft. Equivalent Length Near-Boiler Piping - Space Heating Circulator

Boiler Model

APX399 1½ 1½ 2 2 30.2 12.0

APX500 1½ 1½ 2 2 37.8 13.9

APX800 2 2 2½ 2½ 60.8 21.5

Notes:

* Circulator Models shown are not equipped with internal ow check valve (IFC).

Boiler Supply

Connection,

Inch, FPT

When selecting Circulators with IFC contact Circulator Manufacturer for sizing information. Near-Boiler Piping Size shown is based on 2 to 5.5 Ft/Sec. velocity range to avoid potential noise and pipe erosion.

Boiler Return

Connection,

Inch, FPT

Near-Boiler

Piping Supply

Pipe Size, Inch

Near-Boiler

Piping Return

Pipe Size, Inch

Flow, GPM

@ 25°F Temp.

Differential

Combined Boiler

& Piping Loop

Head Loss, Ft.

* Recommended Circulator

Make & Model

Taco 2400-20 Grundfos UPS

32-80/2 F (second speed)

Taco 2400-30

Grundfos UPS

32-80/2 F (third speed)

40-80/2 F (second speed)

Taco 1400-70 Grundfos UPS

50-80/2 F (third speed)

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

C. Standard Installation Requirements.

Observe the following guidelines when making the

actual installation of the boiler piping:

1. Safety Relief Valve (Required) - The relief valve is packaged loose with boiler and must be installed in the location shown in Figure 35 “Factory Supplied Piping and Trim Installation”. The relief valve must be installed with spindle in vertical position. Installation of the relief valve must comply with ASME Boiler and Pressure Vessel Code, Section IV. The standard factory shipped relief valve is rated for 50 PSI maximum working pressure. Optional 80 PSI and 100 PSI maximum working pressure rated relief valves are available. If the valve is to be replaced, the replacement valve must have a relief capacity equal or exceeding the boiler AHRI Gross Output rating (model APX500). Pipe the relief valve discharge to a location where hot water or steam will not create hazard or property damage if the valve opens. The end of the discharge pipe must terminate in an unthreaded pipe. If the relief valve is not piped to a drain, it must terminate at least 6” above

the oor. Do not run 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.

WARNING

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. Circulator (Required) – Usually at least two circulators will be required to properly install a Apex™ Series boiler. See Paragraph B above for information on sizing the circulators.

3. Expansion Tank (Required) – If this boiler is replacing an existing boiler with no other changes in the system, the old expansion tank can generally be reused. If the expansion tank must be replaced, consult the expansion tank manufacturer’s literature for proper sizing.

4. 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.

5. 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.

6. 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 200°F. Wire the limit per Figures 44 and 45A, in Section VIII “Electrical”.

7. Y-strainer (Recommended) – A Y-strainer or equivalent strainer removes heating system debris from hydronic systems and protects boiler heat exchanger from fouling up. Install the strainer downstream of full port isolation valve, at the inlet side of the circulator, for easy service.

8. 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.

9. 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.

10. Drain Valve (Required) – Drain valve is packaged loose with boiler and must be installed in the location shown in Figure 35 “Factory Supplied Piping and Trim Installation”.

11. Low Water Cutoff (Required by some Codes) – LWCO with harness and LWCO transformer are available as optional components. Order Complete Kit (Part No. 102097-01) when required.

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

Table 16: Fitting and Valve Equivalent Length

(cont’d)

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 (thru 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 16 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 (thru 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) 42.0 60.0 63.0 83.0

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

NOTICE

The Apex (APX) 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 12 PSI.

•

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 warmest

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 36: Near Boiler Piping - Heating Only

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

Figure 37: 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 (APX) 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 38A and 38B. 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 17: Multiple Boiler Water Manifold Sizing

Number of Units

Boiler Model

APX399 2½” 3” 3” 4” 5” 5” 5” APX500 3” 4” 4” 5” 5” 6” 6” APX800 3” 5” 5 6” 6” 8” 8”

2 3 4 5 6 7 8

Recommended Minimum Common

Water Manifold Size (NPT)

Figure 38A: 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 38B: 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 17

and Figures 39B and 40B.

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 a specic model coil ow

and pressure drop. Refer to Table 18 and Figures 40A and 40B.

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

Figure 39A: 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

Installing a low water cutoff in the system piping

of Multiple boilers is strongly recommended and

may be required by Local Codes.

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

Figure 39B: Multiple Boiler Water Piping w/Domestic Hot Water Heater (Page 2 of 2)

CAUTION

Figure 40A: Alternate Multiple Boiler Water Piping w/ Indirect Domestic Hot Water Heater (Page 1 of 2)

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

It is the installers responsibility to select pumps

and boiler piping congurations that provide the

proper ow rates and performance for the boiler

and indirect water heater.

Refer to Table 15 for recommended Boiler Loop

Circulator.

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

Figure 40B: Alternate Multiple Boiler Water Piping w/Indirect Domestic Hot Water Heater (Page 2 of 2)

Notes

Note 1

Note 2

Figure

Reference

Model for

Alliance SL

*Recommended

Circulator Make &

Boiler,

Combined

Alliance SL

Models to

Alliance SL

of Near-Boiler

installed as Part

Loss, Ft

& Piping

Loop Head

Alliance SL

Required

Coil Head

Flow Rate

Loss, Ft @

Coil

GPM

Required

Flow Rate,

Piping

As Part of

Near-Boiler

be installed

Piping

SL27 6 9

40A & 40B

*Not

SL35 6 9

SL50 6 9.5

SL70 6 10

SL27 6 9

SL119 14 17.0

and 2)

(see Notes 1

Recommended

SL35 6 9

SL50 6 9.5

SL70 6 10

SL119 14 17.0

SL27 6 9

SL35 6 9

SL50 6 9.5

SL70 6 10

SL119 14 17.0

Flow thru

Min Req’d

Flow,

Max

Allowable

Near-

Boiler

Piping

Near-Boiler

Boiler

GPM

Boiler,

@ 35°F

GPM

@ 25°F

20°F

Boiler,

GPM @

Flow thru

Pipe

Size,

Return

Inch

Supply

Pipe Size,

Return

Inch, FPT

Connection,

Supply

Inch, FPT

Connection,

Inch

(Note 2)

37.7 30.2 21.5

1-1/2 1-1/2 2 2

Boiler

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

Table 18: Recommended Circulator Models for Apex (APX) Boilers and Alliance SL Indirect Water Heaters

Installed as Part of Near-Boiler Piping Up to 75 Ft. Equivalent Length - Domestic Hot Water Circulator

Model

APX399

APX500 47.2 37.8 27.0

APX800 2 2 2½ 2½ 76.0 60.8 43.4

* The IWH may be installed as part of Boiler piping when boiler DHW modulation rate (input) is adjusted to closely match the IWH rated heating capacity required to satisfy DHW demand (see Figures 40A and 40B).

NOTES:

Note 1: All Alliance SL Coil Flow Rates are below Min Required Flow Rate thru Boiler corresponding to boiler maximum ring rate. These Alliance models can only be installed as separate heating zone off system header - see

Figure 39A and 39B for IWH piping.

Indirect Water Heater Circulator must be selected by an installer based on Alliance SL required coil ow and corresponding coil head loss shown as well as total equivalent length of such separate zone.

Note 2:

IMPORTANT – Shared or Isolated DHW Demand

When the IWH parameter is set to “Primary Piped”, the Sequence Master will be sequencing all required boilers to satisfy the DHW setpoint (default 180°F). Do not use the “Boiler Piped” parameter for 500 and 800 models,

unless IWH is piped off an individual boiler having DHW modulation rate (input) adjusted to closely match the IWH rated heating capacity required to satisfy DHW demand. Otherwise, piping an IWH of an individual boiler could

cause higher than normal velocities or DT’s thru that boiler because of required IWH ow. For commercial applications, it is recommended to pipe IWH’s off the common header piping. A header sensor must be installed to

prevent rapid header temperature rise when the Sequence Master is sequencing all required boilers to satisfy the DHW setpoint (default 180°F).

Note 3: Near-Boiler Piping Size shown is based on 2 to 5.5 Ft/sec velocity range to avoid potential noise and pipe erosion.

VII. Gas Piping

Minimum gas valve inlet pressure is stamped on

WARNING

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.

WARNING

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. Actual point of delivery pressure may be less; contact gas supplier for additional information.

Table 19A: Maximum Capacity of Schedule 40 Black Pipe in CFH* (Natural Gas) For Gas Pressures of 0.5 psig or Less

Inlet Pressure 0.5 PSI or less; 0.3 Inch W.C. 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 11 4 104 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.

10 20 30 40 50 60 70 80 90 100

For materials or conditions other than those listed

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 19A (natural gas) or 19B (LP gas) for maximum capacity of Schedule 40 pipe. Table 20

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 or less can be sized

directly from Tables 19A or 19B, unless authority

having jurisdiction species a gravity factor be applied. For specic gravity greater than 0.60, apply gravity factor from Table 21. If exact specic

gravity is not shown choose next higher value.

above, refer to National Fuel Gas Code, NFPA 54/ANSI Z223.1, or size system using standard engineering methods acceptable to authority having jurisdiction.

Length of Pipe, Ft.

Inlet Pressure 0.5 PSI or less; 0.5 Inch W.C. 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)

B. Connect boiler gas valve to gas supply system.

WARNING

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.

WARNING

Table 19B: Maximum Capacity of Schedule 40 Black Pipe in CFH* (LP Gas) For Gas Pressures of 0.5 psig or Less

Inlet Pressure 11.0 Inch W.C.; 0.3 Inch W.C. 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 Inch W.C.; 0.5 Inch W.C. 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 11 4 101 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 20: Equivalent Lengths of Standard Pipe Fittings & Valves

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

180 Close

Return

Bend

Flow Thru

Gate Globe Angle

Swing Check

45°

Elbow

90°

Elbow

90 Tee

Run

90 Tee, Flow

Thru Branch

VII. Gas Piping (continued)

Table 21: 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

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, NFPA 54/ANSI Z223.1.

2. Use thread (joint) compounds (pipe dope) resistant

to action of liqueed petroleum gas.

3. Apex (APX) boilers have factory supplied Miscellaneous Part Cartons (P/N 102942-03 – APX500, or, P/N 103259-01 – APX800), which include gas-piping 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:

APX500

a. Locate and remove the ¾” NPT x 6” long black

b. APX500 boiler has ¾” NPT x 12” long black

c. Mount the ¾” NPT external gas shutoff valve

d. Install sediment trap, ground-joint union and

APX800

e. Locate and remove 1” NPT external gas shutoff

f. APX800 boiler has 1” NPT x 3” long black

g. Mount the 1” NPT external gas shutoff valve

h. Install sediment trap, ground-joint union and

Correction

Factor

Specic

Gravity

Correction

Factor

nipple and ¾” NPT external gas shutoff valve (required for APX500).

nipple and left side panel grommet factory installed (disregard the supplied ¾” NPT x 6” long black nipple in the Miscellaneous Part Carton).

onto the nipple threaded end outside of the jacket left side panel.

manual shut-off valve upstream of mounted factory supplied manual shut-off valve. See Figure 41 “ Recommended Gas Piping ”.

valve.

nipple and left side panel grommet factory installed.

onto the nipple threaded end outside of the jacket left side panel.

manual shut-off valve upstream of mounted factory supplied manual shut-off valve. See Figure 41 “ Recommended Gas Piping”.

Figure 41: Recommended Gas Piping

4. All above ground gas piping upstream from manual shut-off valve must be electrically continuous and bonded to a grounding electrode. Do not use gas piping as grounding electrode. Refer to National Electrical Code, NFPA 70.

C. Pressure test. See Table 22 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, boiler and its individual shutoff valve must be disconnected from gas supply piping. For testing at ½ psig or less, isolate boiler from gas supply piping by closing boiler’s individual manual shutoff valve.

2. Locate leaks using approved combustible gas noncorrosive leak detector solution.

Table 22: Min./Max. Pressure Ratings

Boiler Model

No.

APX399 14 4,0

APX800

Natural/LP

Gas Max.

Pressure

(in. w.c.)

13.5 4.5

Natural Gas

Min. Pressure

Inlet to Gas Valve

(in. w.c.)

LP Gas

Min. Pressure

Inlet to Gas

Valve

(in. w.c.)

11.0APX500

DANGER

Do not use matches, candles, open ames or

other ignition source to check for leaks.

D. Apex Models 500 and 800 (if equipped with optional

low and high gas pressure switches):

1. The low gas pressure switch must be reset after the boiler is piped to the gas supply and before it is

red.

VII. Gas Piping (continued)

2. For the low and high gas pressure switches proper operation, the boiler inlet gas pressure must be within 4.5” w.c. to 13.5” w.c range.

3. The gas pressure can be measured at the gas valve inlet pressure port. Refer to Figure 42 “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 41.

OUTLET

TEST

PORT (P2)

3. An additional gas pressure regulator(s) may need to be installed to properly regulate inlet gas pressure at the smallest individual module (boiler).

WARNING

If gas pressure in the building is above ½ psig,

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.

OUTLET TEST PORT (P2)

LOW PRESSURE

SWITCH

MANUAL RESET

BUTTON

MANUAL

GAS SHUTOFF

VALVE

SIZE 500 ONLY

LEFT SIDE PANEL & BLOWER

OMITTED FOR CLARITY

Figure 42: Gas Inlet Pressure Tap and Pressure Switch Location

INLET

TEST

PORT (P1)

MANUAL RESET BUTTON

HIGH PRESSURE SWITCH

LOW PRESSURE

SWITCH

MANUAL RESET

BUTTON

6" LONG PIPE NIPPLE

(USED ON 500 ONLY)

PRESSURE SWITCH

SIZE 625 THRU 800

RIGHT SIDE PANEL & BLOWER

OMITTED FOR CLARITY

ASSEMBLY

INLET TEST PORT (P1)

HIGH PRESSURE

SWITCH

MANUAL RESET BUTTON

4" NPT PIPE PLUG

(USED ON 625 THRU 800) PART OF FACTORY

INSTALLED GAS TRAIN.

VIII. Electrical

DANGER

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

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.

NOTICE

All wire, wire nuts, controls etc. are installer supplied unless otherwise noted.

A. General. Install wiring and electrically ground boiler

in accordance with authority having jurisdiction or, in the absence of such requirements, follow the National Electrical Code, NFPA 70, and/or 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 three (3) boiler wires (black, white and green) located in the junction box at the inside top of the boiler jacket.

C. Refer to Figures 43 and 44 or details on the internal

boiler wiring.

Line Voltage (120 VAC) Connections - see Figure 44.

1. The line voltage connections are located in the junction box on the left side of the vestibule. The terminal block TB-1 in conjunction with terminal

screw 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

VIII. Electrical (continued)

Low Voltage (24 VAC) Connections - see Figure 44.

3. The terminal block TB-2 in conjunction with

terminal screw identication label is attached to

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

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, 300Volt 60°C shielded cable. Connect one end of the shielding on this cable to ground.

WARNING

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 boilers current draw is provided in Table

23. 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 23: Boiler Current Draw

Model Number

APX399 <7

APX500 <6

APX800 <8

E. 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 CSA C22.1 Electrical Code. 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.

F. 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 amultiple boiler control system. The Tekmar Model 264 and Model 265 based control wiring diagrams (Figures 44A and 44B) are provided as examples of typical multiple boiler control systems.

Nominal Current

(amps)

VIII. Electrical (continued)

Figure 43: Ladder Diagram

VIII. Electrical (continued)

Figure 44: Wiring Connections Diagram

VIII. Electrical (continued)

Figure 45A: 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 45B: 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 46: 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 47A: 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 47B: 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. 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 Figures 39A and 40A for installation location and Figure 48 or 49 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 43 and 44 terminal J3 for wiring location.

Figure 48: Recommended Direct Immersion

Header Sensor Installation Detail

Figure 49: Alternate “Immersion” type Header

Sensor Installation Detail

VIII. Electrical (continued)

G. Multiple Boiler Operating Information (continued)

1. Required Equipment and Setup (continued)

Figure 50: RJ45 Splitter Installation Detail

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

50.

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

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.

WARNING

Completely read, understand and follow all instructions in this manual before attempting start up.

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. Chlorides< 50 ppm If system contains aluminum components, pH

must be less than 8.5 Total Dissolved Solids - less than 2500 PPM Hardness - 3 to 9 grains/gallon.

Pressurize the system to at least 12 PSI. Purge air from

the system.

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

14 in. w.c. or less. Refer to Table 22 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.

WARNING

The maximum operating pressure of this boiler is 30 psig, 50 psig, 80 psig or 100 psig depending on the model and relief valve option selected. Never exceed these pressures. Do not plug or change pressure relief valve.

E. Conrm that the boiler and system have no water

leaks.

F. Prepare to check operation.

1. Obtain gas heating value (in Btu per cubic foot)

DANGER

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 lighting instructions, see

Figure 51. After the boiler is powered up, it should go through the following sequence. Refer to Section X, “Operation” to locate and view sequence status.

IX. System Start-up (continued)

Apex™ Series Lighting and Operating Instructions

Figure 51: Lighting 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

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.

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,

it may take several tries for ignition before a ame is

established. If more than 5 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

52). 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.

WARNING

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. 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 “Checking/

Adjusting Gas Input Rate”.

L. Checking /Adjusting Gas Input Rate

1. Turn off gas supply to all appliances other than gas-

red boiler.

2. Light main burner by adjusting thermostat to highest setting.

3. Clock gas meter for at least two (2) revolutions of the dial typically labeled ½ or 1 cubic foot per revolution on a typical gas meter.

4. Determine gas ow rate in Cubic Feet per Hour

based on elapsed time for two 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. Compare measured input rate to input rate value stated on rating label. Strive to adjust the boiler input rate within 88% to 100% of the value listed on the boiler rating label.

8. If measured input is too high, reduce input rate by rotating gas valve throttle screw clockwise (see Figure 53) in ¼ turn increments and checking the rate after every adjustment until the measured input rate value falls within 88% to 100% of the

IX. System Start-up (continued)

Figure 52: Burner Flame

value listed on the boiler rating label. If a boiler is equipped with two gas valves, throttle screw adjustments must be done to both gas valves equally and simultaneously.

9. If measured input is too low, increase input rate by rotating gas valve throttle screw counterclockwise (see Figure 53) in ¼ turn increments and checking the rate after every adjustment until the measured input rate value falls within 88% to 100% of the value listed on the boiler rating label. If a boiler is equipped with two gas valves, throttle screw adjustments must be done to both gas valves equally and simultaneously.

10. To lock the boiler in low re, select “Low” from

manual control screen. If measured % O

on LF,

is out of spec (see Table 24 or 26), then turn offset screw clockwise (see Figure 53) to lower % O2 or vice versa.

WARNING

Offset screw on each Apex Series boiler is

adjusted at the factory to the specication. DO

NOT touch the offset screw if measured 02 on Low Fire is in the spec (see Table 24 or 26).

probe directly into ue sensor port. Reinstall the sensor

and the cap upon combustion testing completion.

Check CO2 (or O2) and CO at both high and low re.

The boiler may be locked into high of low re as

follows:

1. To lock the boiler in high re enter the Manual control screen by rst entering the Adjust screen. To

access the Adjust screen, touch the Adjust button, then Login using the contractor password “076”. Press Save and then select the adjust button. Enter the Manual Control button and select “High”. Allow the boiler to operate for approximately 5 minutes before taking combustion readings.

2. To lock the boiler in low re select “Low” from

the Manual Control screen. Allow the boiler to operate for approximately 5 minutes before taking combustion readings.

3. Normal modulation of the boiler will only occur after the “Auto” button is selected in the Manual Control screen.

Typical CO2 readings are shown in Table 24 (Natural

Gas or Table 26 (LP Gas).

WARNING

11. Once the boiler input rate adjusted/conrmed, recheck main burner ame and perform combustion

test as described below (see Paragraph L “ Perform Combustion Test”).

12. Upon completion, return other gas-red appliances

to previous condition of use.

M. Perform Combustion Test

Boilers are equipped with Flue Temperature Sensor

installed into:

• Flue sensor port of boiler CPVC/PVC two-pipe

vent system connector - See Figures 5 and 16.

• Flue sensor port of boiler concentric vent collar -

see Figure 17.

Remove Flue Temperature Sensor and insert the

analyzer probe through Flue Temperature Sensor silicon cap opening, or if required, remove also the Flue Temperature Sensor silicon cap and insert the analyzer

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.

Table 24: Typical Combustion Settings, Natural Gas

Boiler Model

APX399

APX500

APX800

% CO

9.9 - 8.2

(High Fire)

9.3 - 7.9

(Low Fire)

9.3 - 7.9

(High Fire)

9.3 - 7.9

(Low Fire)

Altitude Range

0 - 7000 Ft.

% O2 Range CO, PPM

3.5 - 6.5

(High Fire)

4.5 - 7.0 (Low Fire)

4.5 - 7.0

(High Fire)

4.5 - 7.0

(Low Fire)

Less than

100 PPM

IX. System Start-up (continued)

N. Test External Limits

Test any 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 and, indirect water heater set point supply temperature is set to 170°F. 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 97) of this manual for information on how to do this.

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 boiler models APX399 and APX500 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.

Boiler model APX800 is factory shipped as either

Natural Gas build or LP Gas build. Field conversions of model APX800 are not permitted.

1. Conversion of Apex models APX399 and APX500 from one fuel to another is accomplished using the throttle screw on the gas valve. Figure 53 “Dungs Gas Valve Detail” shows the location of the throttle screw on the Dungs valve. Locate the throttle screw on the boiler being converted.

WARNING

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, install the boiler in accordance with the installation instructions supplied with the boiler. If an installed

Figure 53: Dungs Gas Valve Detail

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) 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 25.

4. Attempt to start the boiler using the lighting 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.

5. After the burner lights, force the burner to high re. Allow the boiler to operate for approximately 5 minutes before taking combustion readings.

6. Check/adjust rate (see Paragraph L), then perform a combustion test (see Paragraph M).

WARNING

The throttle adjustments shown in Table 25 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 26 could result in injury or death from carbon monoxide poisoning.

Table 25: Number of Clockwise Throttle Screw

Turns for LP Conversion

Boiler

Model

APX399

APX500

APX800

Gas Valve

Dungs

GB-057 HO

(¾” NPT)

Dungs

GB-057 HO

(¾” NPT)

Dungs GB-ND057

D01 S00 XP

(¾” NPT)

Throttle Screw Turns at

Altitude Range

0 - 7000 Ft.

1¾

N/A

See Tables 2A & 2B

Notes

IX. System Start-up (continued)

WARNING

These instructions include a procedure for adjusting the air-fuel mixture on this boiler.

This procedure requires a combustion analyzer

to measure the CO2 (or Oxygen) and Carbon

Monoxide (CO) 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.

7. While the burner is at high re adjust the throttle as

needed to obtain the CO Table 26:

• To reduce the CO2 (increase the O2) turn the throttle

clockwise

• To increase the CO2 (reduce the O2) turn the throttle

counter-clockwise

Make adjustments in increments of 1/8 to 1/4 turn and

allow the boiler at least a minute to respond to each adjustment before making another. In general, the CO level will be at its lowest somewhere in the CO2 range shown in this table.

8. Verify that the gas inlet pressure is between the upper and lower limits shown in Table 22 with all gas appliances

(or O2) settings shown in the

(including the converted boiler) both on and off.

9. A label sheet is provided with the boiler for conversions from natural to LP gas. Once conversion is completed, apply labels as follows:

• Apply the “Rating Plate Label” adjacent to the

rating plate.

• Apply the “Gas Valve Label” to a conspicuous area

on the gas valve.

• 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.

Table 26: Typical Combustion Settings, LP Gas

Altitude Range

Boiler Model

APX399

APX500

APX800

% CO

11.4 - 9.5

(High Fire)

11.4 - 9.1

(Low Fire)

10.8 - 9.1

(High Fire)

10.8 - 9.1

(Low Fire)

0 - 5000 Ft.

5001 - 10000 Ft.

% O2 Range CO, PPM

3.5 - 6.5

(High Fire)

3.5 - 7.0

(Low Fire)

4.5 -7.0

(High Fire)

4.5 - 7.0

(Low Fire)

Less than

100 PPM

NOTICE

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.

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:

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

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

If the boiler appears to operate with air deciency, turn the throttle clockwise to increase the amount of Excess Air to the burner.

As the throttle is turned clockwise, the CO2 level will rise, eventually peaking @ 11.8% or 13.8%, depending of the type of gas being used, before falling (conversely, O2 level will drop to 0% before rising). After this happens, continue turning the throttle clockwise, until CO2 level drops (or O2 level increases) to the values shown in Table 24 or Table 26.

WARNING

The pressure regulator (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 pressure regulator. Attempting to adjust the pressure regulator unnecessary, will result in damage to the gas valve and may cause property damage, personal injury or loss of life.

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

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

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

optional eld installation of low water cut-off and 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.

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 lead-

lag sequencer for up to eight (8) boilers capable of auto rotation, outdoor reset and peer-to-peer communication. The peer-peer network is truly “plug and play”. Communication is activated by simply connecting a RJ45 ethernet cable between boilers. The Control provides precise boiler coordination by sequencing boilers based on both header water temperature and boiler modulation

rate. For example, the lead boiler can be 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

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.

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

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 27: 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 The Control starts and stops the boiler and modulates

3. Central Heat Setpoint Upon a Central Heat call for heat the setpoint is either

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 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.

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 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. The automatic reset high limit is provided by a supply manifold mounted Limit Device. The automatic high limit is set to 200°F. The Control monitors a supply water temperature sensor that is also mounted in the supply water manifold and supplies an internal, manual reset high limit. If supply water temperature exceeds 190°F, the control begins to reduce the blower maximum speed setting. If the temperature exceeds 200°F, a forced recycle results. If the temperature exceeds 210°F, 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 the control begins to reduce the maximum blower speed. If temperature difference exceeds 53°F a forced boiler recycle results. If the temperature difference exceeds 63°F 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. Low Water Cut Off (LWCO) The Control shuts down the boiler when either the

supply water temperature is too high or supply to return temperature differential temperature is too high. This ensures the boiler is shutdown in the event of a low water

level or low water ow condition.

Some codes and jurisdiction may accept these integral

features instead of requiring a low water cutoff. ADHERE TO ALL LOCAL CODE REQUIREMENTS. Contact your local code inspector prior to installation. If required, a LWCO four-position wire harness connection is provided for an external LWCO kit (p/n 102097-01) to be added. If the LWCO 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.

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 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, low water cutoff (optional), 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, the control begins to reduce the maximum

blower speed. If the ue temperature exceeds 194°F, a forced boiler recycle results. If the ue temperature

exceeds 204°F, 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:

• APX399 - the control retries ve (5) times and

then goes into soft lockout for one hour.

• APX500 and APX800 - the control retries one (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 28: Frost Protection

Device

Started

Boiler & System

Pump

Boiler Supply Water < 38°F Supply Water > 50°F

Start

Temperatures

Outside Air < 0°F

Supply Water < 45°F

Stop

Temperatures

Outside Air > 4°F

Supply Water > 50°F

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 The Sequence Master responds to Central Heat, DHW

and frost protection demands similar to the stand alone boiler. For example, when selected and DHW priority is active, the sequence master uses DHW setpoint, “Diff Above”, “Diff Below” and pump settings.

7. Shared or Isolated DHW Demand When the Indirect Water Heater (IWH) parameter is set

to “Primary Piped” the Sequence Master sequences all required boilers to satisfy the DHW setpoint (default 180 F). When “Boiler Piped” is selected only the individual slave boiler, with the wired DHW demand and pump,

res to satisfy the DHW setpoint.

8. DHW Two boiler Start When the Indirect Water Heater (IWH) parameter is set to

“Primary Piped” and the DHW Two Boiler Start parameter is set to “Enabled” two boilers are started without delay in response to a DHW call for heat. This feature allows rapid recovery of large IWH’s and multiple IWH’s.

9. Optimized Boiler Modulation

Boiler 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.

10. Innovative Condensing Boiler Control

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.

11. Advanced Boiler Sequencing 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.

12. Stop All Boilers All boilers are stopped without delay if the Call for Heat

input is removed or if the header temperature is higher

than 195°F (eld adjustable).

X. Operation E. Boiler Sequence Of Operation (continued)

E. Boiler Sequence of Operation

1. Normal Operation

Table 29: 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

Priority:

Central Heat

Status:

Standby

Priority:

Central Heat

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

Priority:

Central Heat

Status:

Direct

ignition

Priority:

Central Heat

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 54)

Central Heat

Domestic

Hot Water

Detail Menu

(see Figure 55)

Outdoor

Reset Curve

Active Faults

Lockout

History

Service

Contract

Help Menu

(see Figure 60)

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 56)

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

Domestic Hot Water Off

180 F 180 F

Rate

Priority:

Status: Standby

Heat Demand

Sequence Master Off

Frost Protection Off

Central Heat

Central Heat On

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

Frost Protection On Exercise On

Status

Supply

180 F

Return

160 F

Stack

147 F

Rate

40 %

System On 98

Boiler On 23

DHW Off 0

Figure 54: Status Screens

i Active

Status:

Information found at the bottom of the Status screen and on the Home screen. Table 29 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

Fault

Trends

Flame

2.5 hour trend

Flame

5 minute trend

Boiler Cycles/Hours

Boiler Cycles

Run Time Hours

Supply / Return

Firing Rate

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:

” symbol appears to the right

The “

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

a t e r

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 55: 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

Setpoint

Rate

100%

Priority:

132 F 180 F

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

CLRES

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 56: 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 show 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:

Anti-Short Cycle Time

Device

Started

Boiler & System Outside Air < 0°F Outside Air > 4°F

Start

Temperatures

Stop

Temperatures

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

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

See Table 302500 - Maximum

button to access the following parameters:

Range /

Choices

See Table 30

Minimum to

Maximum

Modulation

Minimum to

Maximum

Modulation

Minimum

- 100 to

Maximum

Light-off Rate

Parameter and Description

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.

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.

Table 30: Parameters Changed Using the Boiler Type Parameter Selections:

Sage2.1 Controller - P/N 104471-01

Spare Part:

Altitude 0 -7000 ft. 0 - 5000 ft.

Boiler Type

Maximum Modulation Rate 7600 5900 5200 5150

Minimum Modulation Rate 2100 1400 1200 1200

Absolute Maximum Modulation Rate 8500 6550 5900 5600

NOTE: Maximum Modulation Rates are designed for 100% nameplate rate at 0°F combustion air. Contact factory before

attempting to increase the Maximum Modulation Rate.

Maximum Light-off Rate

= 4000

399

-07

Sage2.1 Controller - P/N 104471-04

Maximum Light-off Rate

= 4000

500

-07

800N

-05

800P

-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: Pump is disabled and not shown on status screen. Any Demand: Pump Runs during any call for heat.

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

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: Pump Runs during central heat and frost protection call for heat. Pump does not start for a DHW call for heat and will be forced off if there is a DHW call for heat and Domestic Hot Water

Priority is active.

Domestic Pump run pump for:

Activates the Domestic pump output according to selected function. Never: Pump is disabled and not shown on status screen.

Primary Loop Piped IWH: Pump Runs during domestic hot water call for heat. Domestic Hot Water Priority enable/disable

does not affect pump operation.

Boiler Piped IWH: Pump Runs during domestic hot water call for heat. Pump is forced off during a central heat call for heat when Domestic Hot Water Priority “disabled” is selected and when Domestic Hot Water Priority “enable” has been selected and the DHW call for heat has remained on for longer than 1 hour (priority protection time).

Example Pump Parameter selections:

Single boiler with no Indirect Water Heater

Parameter Selections:

System Pump= “any demand” Boiler Pump = “any demand”

DHW Pump = “never”

Explanation:

This piping arrangement only services central heat. When there is any demand both boiler and system pumps

turn on.

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:

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:

“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.

Low

“Press” “Low” to select

manual firing rate control

and Minimum firing rate %

Manual Speed Control

0 RPM 0%

Status Auto

press to change mode

High

“Press” “High” to select

manual firing rate control

and Central Heat

Maximum firing rate %

Auto

Selecting “Low” or “High”

locks (manual mode) firing

rate at min or max Rate %.

After combustion testing select

“Auto” to return the boiler to

Press “Auto”

to return

firing rate to

Automatic

Mode

NOTE

normal operation.

X. Operation G. Changing Adjustable Parameters (continued)

Domestic

Hot Water

Central

“Press”

Factory

Setting

180°F

170°F

5°F 2°F to 10°F

7°F 2°F to 30°F

3 1 to 5

Heat

Range /

Choices

80°F to

190°F

80°F to

190°F

button to access the following parameters:

Parameter and Description

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

160°F

5°F 2°F to 10°F

7°F 2°F to 30°F

Enable

Minutes

3 1 to 5

Range /

Choices

80°F to

190°F

80°F to

190°F

Enable

Disable

30 to 120

Minutes

button to access the following parameters:

Parameter and Description

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

room temperature mode.

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 -40°F to 100°F

70°F 32°F to 100°F

110°F 70°F to 190°F

130°F 80°F to 190°F

0 Minutes

button to access the following parameters:

Range /

Choices

0-1800 Seconds

(0-30 Minutes)

Parameter and Description

Outdoor Reset Enable

If an outdoor sensor is installed and Outdoor Reset is Enabled, the boiler will automatically adjust the heating zone set point temperature based on the outdoor reset curve in Figure 57. The maximum set point is dened by the Central Heat Setpoint (factory set to 180°F) when the outdoor temperature is 0°F or below. The minimum set point temperature shown is 130°F (adjustable as low as 80 F) when the outdoor temperature is 50°F or above. As the outdoor temperature falls the supply water target temperature increases. For example, if the outdoor air temperature is 30°F, the set point temperature for the supply water is 150°F.

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. 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 to 190°F Fan Coil

160 to 190°F

130 to 160°F

Figure 57: Outdoor Reset Curve

Heating Element Type

Convection

Baseboard

Fin Tube

Convective

Radiant

Baseboard

Central Heat

Setpoint

100 to 140°F

130 to 160°F

140 to 160°F Radiators

Heating Element Type

In Slab Radiant High

Mass Radiant

Staple-up Radiant

Low Mass Radiant

X. Operation G. Changing Adjustable Parameters (continued)

Remote 4-20mA

Sequence

Master

Sequence

Slave

“Press”

Factory Setting

Local

130°F

180°F

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

“Press”

Factory Setting

Disable

Boiler Piped

Disabled

120 Secs 120 - 1200 Secs

195°F

50% 50% - 100%

3 1-5

button to access the following parameters:

Range /

Choices

Central Heat Modulation Source

Local,

4-20mA

Local,

4-20mA

80°F -

Central Heat

Setpoint

80°F -

Central Heat

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:

Range / Choices Parameter and Description

Enable, Disable

Boiler Piped,

Primary Piped

Enable, Disable

Central Heat

Setpoint,

195°F

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

100

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.

Burnham Apex Installation and Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual