Burnham Apex Installation And Operation Manual

2015-06-08

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103022-04 - 8/13 Price - $5.00

WARNING: Improper installation, adjustment, alteration, service or maintenance can cause property damage,

injury, or loss of life. For assistance or additional information, consult a qualied installer, service agency or the

gas supplier. This boiler requires a special venting system. Read these instructions carefully before installing.

INSTALLATION, OPERATING AND

SERVICE INSTRUCTIONS FOR

APEX™

CONDENSING HIGH EFFICIENCY

DIRECT VENT

GAS - FIRED HOT WATER BOILER

9700609

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 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.

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.

DANGER

Indicates an imminently hazardous situation

which, if not avoided, will result in death, serious

injury or substantial property damage.

CAUTION

Indicates a potentially hazardous situation which,

if not avoided, may result in moderate or minor

injury or property damage.

WARNING

Indicates a potentially hazardous situation which,

if not avoided, could result in death, serious injury

or substantial property damage.

NOTICE

Indicates special instructions on installation,

operation, or maintenance which are important

but not related to personal injury hazards.

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 instruc-

tions, 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

ASME Boiler and Pressure Vessel Code, which provide a

maximum heat transfer and simultaneous protection against

ue gas product corrosion. These boilers are not designed

for use in gravity hot water space heating systems or

systems containing signicant amount of dissolved oxygen

(swimming pool water heating, direct domestic hot water

heating, etc.).

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

Dimension

Boiler Model

APX399 APX500 APX800

A - Inch

(mm)

28-7/8

(734)

44-7/8

(1140)

54-9/16

(1384)

B - Inch

(mm)

6-3/16

(157)

22-1/8

(562)

28-3/8

(724)

C - Inch

(mm)

13-1/16

(332)

(737)

34-1/4

(876)

D - Inch

(mm)

23-3/4

(602)

39-11/16

(1008)

48-1/16

(1226)

E - Inch

(mm)

15-13/16

(402)

29-3/8

(752)

33-13/16

(864)

Gas Inlet F

(FPT) 3/4” 3/4” 1

Return G 1-1/2” (FPT) 2” (MPT)

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

4 x 4 6 x 6

Approx. Shipping Weight (LBS) 304 350 430

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

Figure 1A: Apex™ - Model APX399

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)

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) * Output

(MBH)

Net AHRI

Ratings Water

(MBH)

Thermal

Efciency

(%)

Combustion

Efciency (%)

Boiler Water

Volume (Gal.)

Heat Transfer

Area

(Sq. Ft.)

Min. Max.

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.

Apex Series Gas-Fired Boilers

Model

Number

Input (MBH) * Output

(MBH)

Net AHRI

Ratings

Water (MBH)

Thermal

Efciency

(%)

Combustion

Efciency (%)

Boiler Water

Volume

(Gal.)

Heat Transfer

Area

(Sq. Ft.)

Min. Max.

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

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.

II. Unpacking Boiler

CAUTION

Do not drop boiler.

A. Move boiler to approximate installed position.

B. Remove all crate fasteners.

C. Lift and remove outside container.

D. Remove boiler from cardboard positioning sleeve on

shipping skid.

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.

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, mis-

sizing 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.

III. Pre-Installation and Boiler Mounting

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.

Figure 2: Clearances To Combustible and Non-combustible Material

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

Boiler Clearances to Combustible (and Non-

Combustible) 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

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

Approved Direct

Vent System

Vent Pipe

Material

Vent

Pipe

Direction

Enclosure

Vent Pipe

Nominal

Diameter

Minimum

Clearance to

Combustible

Material

Factory Standard

Two-Pipe CPVC/PVC Vent and PVC

Air Intake

* CPVC/PVC

Vertical or

Horizontal

Unenclosed at

all Sides

4” or 6” 1”

Available Optional

Two-Pipe Rigid Polypropylene Vent

(or, Flexible Polypropylene Liner

for Vertical Venting only) and Rigid

Polypropylene or PVC Combustion

Air Intake

Pipe Rigid

Polypropylene

Vent (or,

Flexible

Polypropylene

Liner for

Vertical

Venting only)

80 mm

10 mm

(110 mm)

150 mm

(160 mm)

1”

Available Optional

Two-Pipe Stainless Steel Vent and

Galvanized Steel or Air Intake

Stainless

Steel 4” or 6” 1”

Available Optional

Concentric Inner Polypropylene Vent

and Outer Steel Air Intake

Polypropylene 100/150 mm

(110/160 mm) 0”

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

combustible or non-combustible walls

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 Top Boiler Model

APX399 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.

• 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

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.

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.

Table 4: Vent/Combustion Air System Options

IV. Venting A. General Guidelines (continued)

Approved Direct

Vent System

Vent

Material Orientation Termination Description Figures Component

Table Part

Factory Standard

Two-Pipe,

CPVC/PVC Vent and

PVC Air Intake

CPVC/PVC

Horizontal

Standard

(thru sidewall)

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).

4 thru 9A,

9B, 10 5A

Optional

Snorkel

(thru sidewall)

Same as above but separate snorkel

type terminals.

4 thru 7,

10, 11 5B

Optional

Vertical

(thru roof)

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.

4 thru 6, 10,

12, 13 5C

Available Optional

Two-Pipe, Rigid

Polypropylene

Vent (or Flexible

Polypropylene Liner

for Vertical venting

only) and Rigid

Polypropylene or PVC

Pipe Air Intake

Rigid

Polypropylene

(or Flexible

Polypropylene

Liner for vertical

Venting only)

Horizontal

Standard

(thru sidewall)

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).

4 thru 9A,

9B, 10 9, 10

Optional Snorkel

(thru sidewall)

Same as above but separate snorkel

type terminals.

4 thru 7,

10, 11 9, 10

Optional

Vertical

(thru roof or

chimney/chase)

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.

12 thru 16 9, 10

Available Optional

Two-Pipe,

Stainless Steel Vent

and PVC/Galvanized

Steel Air Intake

Stainless Steel

Horizontal

Standard

(thru sidewall)

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

9A, 9B,

16, 17

11A, 11B D.

Optional Snorkel

(thru sidewall) Same as above but separate snorkel

type terminals. 11, 16, 17

Vertical Vertical (thru roof)

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.

12, 13, 17

Available Optional

Concentric, Inner

Polypropylene Vent and

Outer Steel Air Intake

Polypropylene

Horizontal

(Wall) Terminal Concentric vent/air pipe terminates thru

sidewall. 18 thru 25

12, 13 E.

Vertical Vertical (Roof)

Terminal

Concentric vent/air pipe terminates thru

roof.

18 thru 21,

26 thru 31

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.

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

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)

IV. Venting A. General Guidelines (continued)

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

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.

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.

IV. Venting A. General Guidelines (continued)

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

Vent & Air Intake Components Part

Number

Quantity

APX399 and APX500

Standard Termination

Vent Kit

(P/N 102189-03)

includes

APX800

Standard Termination

Vent Kit

(P/N 103253-01)

includes

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) 103313-01 N/A 2

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 102185-02 1 N/A

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

Gasket 103248-01 N/A 1

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

(Roof) Termination

Vent Components Part

Number

Quantity

APX399 and APX500

Horizontal (Snorkel)

Termination

APX800

Horizontal (Snorkel)

Termination

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

N/A

Supplied by Others

2 N/A

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

Vent Components Part

Number

Quantity

APX399 and APX500

Vertical (Roof)

Termination

APX800

Vertical (Roof)

Termination

4" Schedule 40 PVC Coupler

N/A

Supplied by Others

1 N/A

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

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

(Snorkel) Termination

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

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

Figure 5: Expansion Loop and Offset

2 L

MIN

LONG RUN OF PIPE

CHANGE OF DIRECTION

(VERTICAL OR HORIZONTAL)

LOOP

(HORIZONTAL ONLY)

(TOP VIEW)

OFFSET

(L)

LOOP LENGTH

RESTRAINT (RESTRICTS MOVEMENT)

HANGER (ALLOWS MOVEMENT)

KEY

Nominal

Pipe

Dia. (In.)

Length of

Straight Run

(Ft.)

Loop Length

“L” (In.)

20 60

30 74

40 85

50 95

60 104

20 73

30 90

40 103

50 116

60 127

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.

Table 7: Expansion Loop Lengths

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

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

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”

Figure 7: Near-Boiler Vent/Combustion Air Piping

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.

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)

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.

Quantity

(Pc)

Equivalent

Length, Ft/Pc

Subtotal,

Equivalent

Ft. (A)

Nominal

Diameter,

In.

Quantity

(Pc)

Equivalent Length,

Ft/Pc

Subtotal,

Equivalent Ft.

(D)

4 13 4 1 13 13

6 22 6 1 22 22

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

Nominal

Diameter,

In.

Quantity

(Pc)

Equivalent

Length, Ft/Pc

Subtotal,

Equivalent

Ft. (B)

Nominal

Diameter,

In.

Quantity

(Pc)

Equivalent Length,

Ft/Pc

Subtotal,

Equivalent Ft.

(A)

4 4.5 4 13

6 7.5 6 22

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

Nominal

Diameter,

In.

Quantity

(Length,

Ft.)

Equivalent

Length,

Ft/Ft

Subtotal,

Equivalent

Ft. (C)

Nominal

Diameter, In.

Quantity

(Length, Ft.)

Equivalent Length,

Ft/Ft

Subtotal,

Equivalent Ft.

(B)

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)

Nominal

Diameter,

In.

Quantity

(Length, Ft.)

Equivalent Length,

Ft/Ft

Subtotal,

Equivalent Ft.

(E)

4 2.5 1 2.5

6 2.5 1 2.5

Straight Pipe, PVC (Installer Supplied)

Nominal

Diameter,

Quantity

(Length, Ft.)

Equivalent Length,

Ft/Ft

Subtotal,

Equivalent Ft.

(C)

4 1

6 1

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

* 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.

Boiler

Model

4” Combustion Air Pipe

(Equivalent Length)

6” Combustion Air Pipe

(Equivalent Length)

4” Vent Pipe

(Equivalent Length)

6” Vent Pipe

(Equivalent Length)

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

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.

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.

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:

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

• 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 non-

combustible 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

Figure 9A: Direct Vent - Sidewall Terminations

Figure 8: Wall Penetration Clearances for PVC Vent Pipe

- 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 weather-

tight 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.

Figure 10: Rodent Screen Installation

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

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

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 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° elbow so that 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 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.

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.

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.

Figure 12: Direct Vent - Vertical Terminations

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

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.

Figure 13: Direct Vent - Vertical Terminations

with Sloped Roof

• 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

M&G/DuraVent

PolyPro Single Wall Rigid Vent

PolyPro Flex Flexible Vent (APX399 and

APX500)

Centrotherm

Eco Systems

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)

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.

Boiler

Model

M&G / DuraVent Part Numbers/Sizes

Male Boiler Adapter,

PVC to PP Rigid Pipe Flex Pipe Pipe Joint

Locking Band

Side Wall

Termination Tee

Chimney Kit for

Venting Only

APX399 4PPS-04PVCM-4PPF 100 mm 100 mm 43PPS-LB 43PPS-TB 4PPS-FK

APX500

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

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

Boiler

Model

Centrotherm Eco Part Numbers/Sizes

Male Boiler Adapter,

PVC to PP Rigid Pipe Flex Pipe Pipe Joint

Locking Band

Side Wall

Termination Tee

Chimney Kit for

Venting Only

APX399 ISAA0404

ISSAL0404 110 mm 110 mm IANS04 ISTT0420

IFCK0425

and

IFCK0435

APX500

APX800 ISAA0606

ISSAL0606 160 mm N/A IANS06 ISTT0620 N/A

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

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.

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.

Figure 15: Flexible Vent in Masonry

Chimney with Separate Air Intake

IV. Venting C. Polypropylene Venting (continued)

Venting of Other Appliances (or Fireplace)

into Chase or Adjacent Flues Prohibited!

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.

1. 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.

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. 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.

4. 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.

Vent System

Component

Part Numbers

Equivalent

Feet of Pipe

APX399

and

APX500

APX800

4" Vent 6” Vent

SS Vent Kit 102501-02

N/A

Horizontal Vent Terminal

(Included in Kit) 8116313

PVC to SS Vent Adapter

(Included In Kit) 102220-01

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

Equal to

Installed

Length

(1.06 to 1.64)

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

Table 11A: Burnham Commercial Vent System

Components (Stainless Steel)

Manufacturer Vent

System Size Wall Thimbles Horizontal Termination Vertical

Termination

Protech Systems Inc.. FasNseal 4 FSWT4 Tee: FSTT4 FSBS4

6 FSWT6 Tee: FSTT6 FSBS6

Z-Flex SVE Series III

(“Z-Vent III”)

4 2SVSWTEF04 Tee: 2SVSTTF04 24SVSTPF04

6 N/A N/A N/A

Flex-L Intl. Star-34 4SR04WT15 Tee: SRTT-04 SRTP-04

6 N/A N/A N/A

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

and vent supports.

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

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.

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.

5. 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).

2. 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.

IV. Venting D. Stainless Steel Venting (continued)

Table 12: Concentric Vent Length

Boiler

Model

Inner/Outer

Pipe Dia., mm

Vent Length

(Equiv. Ft.) Wall Opening

Diameter

Minimum * Maximum

APX399 100/150 mm 32 in.

60 6-1/2 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.

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

Part Number Component Description Size

Component

Equivalent Vent

Length, Ft

Comments

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.

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)”.

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

Figure 17: Field Installation of Boiler

Concentric Vent Collar

IV. Venting E. Concentric Polypropylene Venting (continued)

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)

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).

IV. Venting E. Concentric Polypropylene Venting (continued)

Figure 20: Cutting Straight Pipe

Figure 21: Joining Cuttable Pipe

Figure 22: Joining Non-Cuttable Pipe

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.

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

IV. Venting E. Concentric Polypropylene Venting (continued)

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.

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.

5. 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 25: Cutting Vent Terminal Pipe

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

Figure 30: Completing Vertical Terminal Installation

• 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).

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.

F. Removing the Existing Boiler

For installations not involving the replacement of an

existing boiler, proceed to Step B.

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

Figure 31: Chimney Chase Installation

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.

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.

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

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.

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)

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 installer-

supplied 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.

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:

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.

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

V. Condensate Disposal (continued)

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

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:

VI. Water Piping and Trim

Figure 35: Factory Supplied Piping and Trim Installation

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.

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.

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.

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

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

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

Required

Flow,

(GPM)

@ 30°F DT

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.

Table 14: Flow Range Requirement Through Boiler

Pressure Drop vs. Flow

399 500

800

010 20 30 40 50 60 70 80

Flow Rate (GPM)

Pressure Drop (Feet of Head)

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

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

Boiler Supply

Connection,

Inch, FPT

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

APX399 1½ 1½ 2 2 30.2 12.0 Taco 2400-20 Grundfos UPS

32-80/2 F (second speed)

APX500 1½ 1½ 2 2 37.8 13.9

Taco 2400-30

Grundfos UPS

32-80/2 F (third speed)

40-80/2 F (second speed)

APX800 2 2 2½ 2½ 60.8 21.5 Taco 1400-70 Grundfos UPS

50-80/2 F (third speed)

Notes:

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

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.

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.

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.

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)

Table 16: Fitting and Valve Equivalent Length

Copper Fitting and Sweat Valve Equivalent Length (Ft)

Fitting or Valve

Description

Copper Pipe or Valve Size

1 1¼ 1½ 2

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

Threaded Fitting and Valve Equivalent Length (Ft)

Fitting or Valve

Description

Black Threaded Pipe or

Valve Size

1 1¼ 1½ 2

90° Elbow 2.6 3.5 4.0 5.2

Long Radius

Elbow (45° or 90°) 1.4 1.8 2.2 2.8

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) 8.7 12.0 13.0 17.0

Flow-Check Valve (typical) 42.0 60.0 63.0 83.0

Table 16: Fitting and Valve Equivalent Length

(cont’d)

NOTE: Table 16 is provided as reference to assist in piping design and species equivalent length of typical piping ttings and

valves.

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 C. Standard 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.

Table 17: Multiple Boiler Water Manifold Sizing

Boiler Model

Number of Units

2345678

Recommended Minimum Common

Water Manifold Size (NPT)

APX399 2½” 3” 3” 4” 5” 5” 5”

APX500 3” 4” 4” 5” 5” 6” 6”

APX800 3” 5” 5 6” 6” 8” 8”

VI. Water Piping and Trim D. Special Situation Piping Installation Requirements (continued)

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.

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.

Figure 39A: Multiple Boiler Water Piping w/Domestic Hot Water Heater (Page 1 of 2)

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

NOTICE

Installing a low water cutoff in the system piping

of Multiple boilers is strongly recommended and

may be required by Local Codes.

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

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

NOTICE

Installing a low water cutoff in the system piping

of Multiple boilers is strongly recommended and

may be required by Local Codes.

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

CAUTION

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)

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

Boiler

Model

Boiler

Supply

Connection,

Inch, FPT

Boiler

Return

Connection,

Inch, FPT

Near-Boiler

Piping

Supply

Pipe Size,

Inch

(Note 2)

Near-

Boiler

Piping

Return

Pipe

Size,

Inch

(Note 2)

Max

Allowable

Flow thru

Boiler,

GPM @

20°F

Flow,

GPM

@ 25°F

Min Req’d

Flow thru

Boiler,

GPM

@ 35°F

Alliance SL

Models to

be installed

As Part of

Near-Boiler

Piping

Alliance SL

Coil

Required

Flow Rate,

GPM

Alliance SL

Coil Head

Loss, Ft @

Required

Flow Rate

Combined

Boiler,

Alliance SL

& Piping

Loop Head

Loss, Ft

*Recommended

Circulator Make &

Model for

Alliance SL

installed as Part

of Near-Boiler

Piping

Reference

Figure Notes

APX399

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

37.7 30.2 21.5

SL27 6 9

*Not

Recommended

(see Notes 1

and 2)

40A & 40B

Note 1

Note 2

SL35 6 9

SL50 6 9.5

SL70 6 10

SL119 14 17.0

APX500 47.2 37.8 27.0

SL27 6 9

SL35 6 9

SL50 6 9.5

SL70 6 10

SL119 14 17.0

APX800 2 2 2½ 2½ 76.0 60.8 43.4

SL27 6 9

SL35 6 9

SL50 6 9.5

SL70 6 10

SL119 14 17.0

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

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: * 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).

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.

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

VII. Gas Piping

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.

Inlet Pressure 0.5 PSI or less; 0.3 Inch W.C. Pressure Drop

Nominal

Pipe Size, In.

Inside

Diameter, In.

Length of Pipe, Ft.

10 20 30 40 50 60 70 80 90 100

½0.622 131 90 72 62 55 50 46 42 40 38

¾0.824 273 188 151 129 114 104 95 89 83 79

1 1.049 514 353 284 243 215 195 179 167 157 148

1¼ 1.380 1056 726 583 499 442 400 368 343 322 304

1½ 1.610 1582 1087 873 747 662 600 552 514 482 455

2 2.067 3046 2094 1681 1439 1275 1156 1063 989 928 877

2½ 2.469 4856 3337 2680 2294 2033 1842 1695 1576 1479 1397

3 3.068 8584 5900 4738 4055 3594 3256 2996 2787 2615 2470

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; 0.5 Inch W.C. Pressure Drop

Nominal

Pipe Size, In.

Inside

Diameter, In.

Length of Pipe, Ft.

10 20 30 40 50 60 70 80 90 100

½0.622 172 118 95 81 72 65 60 56 52 50

¾0.824 360 247 199 170 151 137 126 117 110 104

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.

Minimum gas valve inlet pressure is stamped on

the rating label located in the boiler’s vestibule

compartment.

2. Maximum gas demand. Refer to the boiler’s input as

printed on its rating label. Also consider existing and

expected future gas utilization equipment (i.e. water

heater, cooking equipment).

3. Length of piping and number of ttings. Refer

to Tables 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.

For materials or conditions other than those listed

above, refer to National Fuel Gas Code, NFPA

54/ANSI Z223.1, or size system using standard

engineering methods acceptable to authority having

jurisdiction.

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.

Inside

Diameter, In.

Length of Pipe, Ft.

10 20 30 40 50 60 70 80 90 100

½0.622 88 60 48 41 37 33 31 29 27 25

¾0.824 184 126 101 87 77 70 64 60 56 53

1 1.049 346 238 191 163 145 131 121 112 105 100

1¼ 1.380 710 488 392 336 297 269 248 231 216 204

1½ 1.610 1064 732 588 503 446 404 371 346 324 306

2 2.067 2050 1409 1131 968 858 778 715 666 624 590

2½ 2.469 3267 2246 1803 1543 1368 1239 1140 1061 995 940

3 3.068 5776 3970 3188 2729 2418 2191 2016 1875 1760 1662

Inlet Pressure 11.0 Inch W.C.; 0.5 Inch W.C. Pressure Drop

Nominal

Pipe Size, In.

Inside

Diameter, In.

Length of Pipe, Ft.

10 20 30 40 50 60 70 80 90 100

½0.622 116 80 64 55 48 44 40 38 35 33

¾0.824 242 166 134 114 101 92 85 79 74 70

1 1.049 456 314 252 215 191 173 159 148 139 131

1¼ 1.380 937 644 517 442 392 355 327 304 285 269

1½ 1.610 1403 964 775 663 588 532 490 456 427 404

2 2.067 2703 1858 1492 1277 1131 1025 943 877 823 778

2½ 2.469 4308 2961 2377 2035 1803 1634 1503 1399 1312 1239

3 3.068 7615 5234 4203 3597 3188 2889 2658 2472 2320 2191

* 1 CFH of LP Gas is approximately equal to 2.5 MBH; contact your gas supplier for the actual heating value of your gas.

Table 20: Equivalent Lengths of Standard Pipe Fittings & Valves

Nominal

Pipe Size,

Inc.

Inside

Diameter,

In.

Valves (Screwed) - Fully Open Screwed Fittings

Gate Globe Angle Swing

Check

45°

Elbow

90°

Elbow

180 Close

Return

Bend

90 Tee

Flow Thru

Run

90 Tee, Flow

Thru Branch

½0.622 0.4 17.3 8.7 4.3 0.7 1.6 3.5 1.6 3.1

¾0.824 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

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.

WARNING

Gas supply to boiler and system must be

absolutely shut off prior to installing or servicing

boiler gas piping.

VII. Gas Piping (continued)

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 non-

corrosive leak detector solution.

Table 21: Specic Gravity Correction Factors

Specic

Gravity

Correction

Factor

Specic

Gravity

Correction

Factor

0.60 1.00 0.90 0.82

0.65 0.96 1.00 0.78

0.70 0.93 1.10 0.74

0.75 0.90 1.20 0.71

0.80 0.87 1.30 0.68

0.85 0.81 1.40 0.66

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

nipple and ¾” NPT external gas shutoff valve

(required for APX500).

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

nipple and left side panel grommet factory

installed (disregard the supplied ¾” NPT x 6”

long black nipple in the Miscellaneous Part

Carton).

c. Mount the ¾” NPT external gas shutoff valve

onto the nipple threaded end outside of the jacket

left side panel.

d. Install sediment trap, ground-joint union and

manual shut-off valve upstream of mounted

factory supplied manual shut-off valve. See

Figure 41 “ Recommended Gas Piping ”.

APX800

e. Locate and remove 1” NPT external gas shutoff

valve.

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

nipple and left side panel grommet factory

installed.

g. Mount the 1” NPT external gas shutoff valve

onto the nipple threaded end outside of the jacket

left side panel.

h. Install sediment trap, ground-joint union and

manual shut-off valve upstream of mounted

factory supplied manual shut-off valve. See

Figure 41 “ Recommended Gas Piping”.

VII. Gas Piping (continued)

Boiler

Model

No.

Natural/LP

Gas Max.

Pressure

(in. w.c.)

Natural Gas

Min. Pressure

Inlet to Gas Valve

(in. w.c.)

LP Gas

Min. Pressure

Inlet to Gas

Valve

(in. w.c.)

APX399 14 4,0

11.0APX500 13.5 4.5

APX800

Table 22: Min./Max. Pressure Ratings

Figure 41: Recommended Gas Piping

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.

Figure 42: Gas Inlet Pressure Tap and Pressure Switch Location

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.

MANUAL

GAS SHUTOFF

VALVE

INLET

TEST

PORT (P1)

OUTLET

TEST

PORT (P2)

SIZE 625 THRU 800

RIGHT SIDE PANEL & BLOWER

OMITTED FOR CLARITY

MANUAL RESET

BUTTON

HIGH PRESSURE

SWITCH

MANUAL RESET

BUTTON

LOW PRESSURE

SWITCH

MANUAL RESET

BUTTON

HIGH PRESSURE

SWITCH

INLET

TEST

PORT (P1)

LOW PRESSURE

SWITCH

SIZE 500 ONLY

LEFT SIDE PANEL & BLOWER

OMITTED FOR CLARITY

6" LONG PIPE NIPPLE

(USED ON 500 ONLY)

34" NPT PIPE PLUG

(USED ON 625 THRU 800)

PART OF FACTORY

INSTALLED GAS TRAIN.

PRESSURE SWITCH

ASSEMBLY

MANUAL RESET

BUTTON

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.

VIII. Electrical

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

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.

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.

VIII. Electrical (continued)

Model Number Nominal Current

(amps)

APX399 <7

APX500 <6

APX800 <8

Table 23: Boiler Current Draw

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.

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

VIII. Electrical (continued)

Figure 45B: Modied Wiring For DHW Priority When Using Low Flow Circulator Piped Off System Header -

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

TACO ZONE VALVES

(SEE NOTE)

HONEYWELL V8043E

ZONE VALVES

RD RD

YE YE

4 5

2 WIRE (24V) THERMOSTATS

W/ HEAT ANTICIPATOR SET

AT 0.9 AMPS (40VA REQ'D

FOR EVERY 6 ZONE VALVES)

FLAIR "VJ"

ZONE VALVES

(SEE NOTE)

TO SAGE2

HEATING T-STAT

POWER

SUPPLY

120/60/1

FIELD INSTALLED

40VA TRANSFORMER

(SEE NOTE)

2 WIRE (24V) THERMOSTATS

W/ HEAT ANTICIPATOR SET

AT 0.9 AMPS (40VA REQ'D

FOR EVERY 3 ZONE VALVES)

2 WIRE (24V) THERMOSTATS

W/ HEAT ANTICIPATOR SET

AT 0.5 AMPS (40VA REQ'D

FOR EVERY 4 ZONE VALVES)

2 WIRE (24V) THERMOSTATS

W/ HEAT ANTICIPATOR SET

AT 0.3 AMPS (40VA REQ'D

FOR EVERY 4 ZONE VALVES)

WHITE ROGERS

#1361-102

ZONE VALVES

CHECK FOR CROSS-PHASING BETWEEN BOILER TRANSFORMER AND FIELD SUPPLIED

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

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

NOTE:

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

SEPARATE GROUND IS MADE IN THE ZONE CIRCUIT.

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)

Tekmar 265 Based Control System (or equal)

Sequence of Operation

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.

Figure 47A: Multiple Boiler Wiring Diagram w/Tekmar 265 Control

VIII. Electrical (continued)

Figure 47B: Multiple Boiler Wiring Diagram w/Tekmar 264 Control

Tekmar 264 Based Control System (or equal)

Sequence of Operation

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.

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)

Step Description Comments

1Install and wire the Header

Sensor

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

NOTE

This step can not be skipped. The Sequence Master can not be “enabled” unless a Header

Sensor is installed.

2Install Ethernet Cables

between boilers

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.

3 Apply Power to All Boilers

4Set Unique Boiler

Addresses

Assign all boilers a unique Boiler Address using any number from 1 through 8.

WARNING

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

5Enable 1 Boiler Master

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

WARNING

When more than one Sequencer Master is enable erratic behavior will result.

6 Power Down All Boilers

Power Up Master

Sequencer

“Enabled” Boiler First

8Power Up Other Boilers

9Conrm Communication

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.

d. Multiple Boiler Setup

Figure 50: RJ45 Splitter Installation Detail

VIII. Electrical (continued)

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.

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)

IX. System Start-up

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.

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

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)

Status Control Action

Initiate Power-up

Standby Delay

This state is entered when a delay is

needed before allowing the burner control

to be available and for sensor errors.

Standby

Boiler is not ring. There is no call for

heat or there is a call for heat and the

temperature is greater than setpoint.

Safe Startup Tests ame circuit then checks for ame

signal.

Drive Purge Driving blower to purge rate setting and

waiting for the proper fan feedback.

Prepurge Purges the combustion chamber for the

10 second purge time.

Drive Light-off Driving blower to light-off rate setting and

waiting for the proper fan feedback.

Pre-ignition

Test

Tests the safety relay and veries that

downstream contacts are off.

Pre-ignition Energizes the igniter and checks for

ame.

Direct

Ignition

Opens main fuel valve and attempts

to ignite the main fuel directly from the

ignition source.

Running

Normal boiler operation. Modulation rate

depends on temperature and setpoint

selections and modulating control action.

Postpurge Purges the combustion chamber for the

30 second purge time.

Lockout

Prevents system from running due to a

detected problem and records fault in

Lockout History.

Figure 52: Burner Flame

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

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.

IX. System Start-up (continued)

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 % O2 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).

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

Boiler

Model

Altitude Range

0 - 7000 Ft.

% CO2% O2 Range CO, PPM

APX399

9.9 - 8.2

(High Fire)

9.3 - 7.9

(Low Fire)

3.5 - 6.5

(High Fire)

4.5 - 7.0

(Low Fire) Less than

100 PPM

APX500

APX800

9.3 - 7.9

(High Fire)

9.3 - 7.9

(Low Fire)

4.5 - 7.0

(High Fire)

4.5 - 7.0

(Low Fire)

Table 24: Typical Combustion Settings,

Natural Gas

Figure 53: Dungs Gas Valve Detail

Table 25: Number of Clockwise Throttle Screw

Turns for LP Conversion

Boiler

Model Gas Valve

Throttle Screw Turns at

Altitude Range

0 - 7000 Ft.

APX399

Dungs

GB-057 HO

(¾” NPT)

1¾

APX500

Dungs

GB-057 HO

(¾” NPT)

APX800

Dungs GB-ND057

D01 S00 XP

(¾” NPT)

N/A

See Tables 2A & 2B

Notes

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

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.

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.

IX. System Start-up (continued)

Boiler Model

Altitude Range

0 - 5000 Ft.

5001 - 10000 Ft.

% CO2 % O2 Range CO, PPM

APX399

11.4 - 9.5

(High Fire)

11.4 - 9.1

(Low Fire)

3.5 - 6.5

(High Fire)

3.5 - 7.0

(Low Fire) Less than

100 PPM

APX500

APX800

10.8 - 9.1

(High Fire)

10.8 - 9.1

(Low Fire)

4.5 -7.0

(High Fire)

4.5 - 7.0

(Low Fire)

Table 26: Typical Combustion Settings,

LP Gas

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 CO2 (or O2) settings shown in the

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

(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.

X. Operation

A. Overview

1. Sage 2.1 Controller

The Sage 2.1 Controller (Control) contains features and

capabilities which help improve heating system operation,

and efciency. By including unique capabilities, the Control

can do more, with less eld wiring, and fewer aftermarket

controls and components – improving the operation of both

new and replacement boiler installations.

2. Advanced Touch Screen Display

180 F

Boiler 1

Energy Save On

Max Efficiency On

Standby

iStatus

Help

Adjust

Detail

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.

6. Warm Weather Shutdown (WWSD)

Some boilers are used primarily for heating buildings,

and the boilers can be automatically shutdown when

the outdoor air temperature is warm. When outside air

temperature is above the WWSD setpoint, this function

will shut down the boiler, boiler pump and/or the system

pump.

7. Domestic Hot Water Priority (DHWP)

Some boilers are used primarily for building space heating,

but also provide heat for the domestic hot water users.

When the outdoor temperature is warm, the outdoor reset

setpoint may drop lower than a desirable domestic hot

water temperature. Also, often it is required to quickly

recover the indirect water heater. When DHWP is

enabled, heating circulators are stopped, the domestic

circulator is started and the domestic hot water setpoint is

established in response to a domestic hot water demand.

Priority protection is provided to allow the heating loop

to be serviced again in the event of an excessively long

domestic hot water call for heat.

8. Energy Management System (EMS) Interface

The control accepts a 4-20mAdc input from the EMS

system for either direct modulation rate or setpoint.

9. Circulator Control

The Control may be used to sequence the domestic hot

water, boiler and system circulators. Service rated relay

outputs are wired to a line voltage terminal block for easy

eld connection. Simple parameter selections allow all

three pumps to respond properly to various hydronic

piping arrangements including either a boiler or primary

piped indirect water heater. Circulators are automatically

run for a 20 second exercise period after not being used

for longer than 7 days. Circulator exercise helps prevent

pump rotor seizing.

10. Multiple Boiler Sequencer Peer-To-Peer Network

The Control includes state-of-the-art modulating 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.

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.

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

Table 27: Order of Priority

Priority

Status

Screen

Display

Boiler Responding to:

1st Sequencer

Control

The boiler is connected to the peer-

to-peer network. The boiler accepts

demand from the Sequencer Master.

2nd Domestic Hot

Water

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.

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

there is no DHW demand or DHW

priority time has expired.

4th Frost

Protection

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.

5th Warm

Weather

Shutdown

(WWSD)

WWSD is active and the boiler will

not respond to central heat demands.

DHW demand is not blocked by

WWSD.

6th Standby There is no demand detected.

2. Setpoint Purpose

The Control starts and stops the boiler and modulates

the boiler input from minimum (MBH) to maximum

(MBH) in order to heat water up to the active setpoint.

The setpoint is determined by the priority (Central Heat

or Domestic Hot Water) and as described in the following

paragraphs.

3. Central Heat Setpoint

Upon a Central Heat call for heat the setpoint is either

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:

Device

Started

Start

Temperatures

Stop

Temperatures

Boiler & System

Pump

Outside Air < 0°F

Supply Water < 45°F

Outside Air > 4°F

Supply Water > 50°F

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

Table 28: Frost Protection

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

Supply 140 F

140 F

Rate 0%

Status:

Setpoint

Boiler 1

Priority: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.

Supply 140 F

140 F

Rate 0%

Status:

Setpoint

Boiler 1

Priority:Central Heat

Standby

Priority:

Central Heat

Status:

Standby

(burner Off, circulator(s) On)

Boiler is not ring. There is a Central Heat call for heat and the Supply temperature

is greater than setpoint minus the “Diff Below”.

Supply 132 F

140 F

Rate 98%

Status:

Setpoint

Boiler 1

Priority:Central Heat

Prepurge 10

Priority:

Central Heat

Status:

Prepurge

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.

Supply 132 F

140 F

Rate 89%

Status:

Setpoint

Boiler 1

Priority:Central Heat

Direct Ignition

Priority:

Central Heat

Status:

Direct

ignition

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.

Supply 132 F

140 F

Rate 100%

Status:

Setpoint

Boiler 1

Priority:Central Heat

Running

Priority:

Central Heat

Status:

Running

(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.

Supply 132 F

180 F

Rate 100%

Status:

Setpoint

Boiler 1

Priority:Domestic Hot Water

Running

Priority:

Domestic

Hot Water

Status:

Running

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

(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.

Priority:

Standby

Status:

Standby

Delay

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.

Priority:

Standby

Status:

Lockout

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.

180 F

Boiler 1

Energy Save On

Max Efficiency On

Standby

iStatus

Help

Adjust

Detail

Home Screen

Help Menu

(see Figure 60)

Detail Menu

(see Figure 55)

Status Screens

(see Figure 54)

Adjust Mode Screens

(see Figure 56)

Supply 180 F

180 F

Rate 0%

Status: Standby

Setpoint

Boiler 1

Priority: Central Heat

iCentral Heat

Domestic

Hot Water

Outdoor

Reset Curve

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

Lockout

History

Service

Contract

Boiler Size

Setup

Sequencer

Setup

Active Faults

Supply 180 F

180 F

Rate 0%

Status: Standby

Setpoint

Boiler 1

Priority: Central Heat

iActive

Fault

180 F

Boiler 1

Energy Save On

Max Efficiency On

Standby

iStatus

Help

Adjust

Detail

Home Screen

Status Screen

Menu Button

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.

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.

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.

Flame

2.5 hour trend

Flame

5 minute trend Firing Rate

Supply / Return ><

Trends

Status

147 F

160 F

Supply 180 F

Rate 40 %

Stack

Return

Supply 180 F

180 F

Rate 0%

Status: Standby

Setpoint

Boiler 1

Priority:Central Heat

2000

800

Boiler Cycles

Boiler Cycles/Hours

Run Time Hours

Pump Status/Cycles

System On 98

Boiler On 23

DHW Off 0

Heat Demand

Central Heat On

Domestic Hot Water Off

Sequence Master Off

Frost Protection Off

Frost Protection On Exercise On

Figure 54: Status Screens

Flame

2.5 hour trend

Flame

5 minute trend Firing Rate

Supply / Return ><

Trends

2000

800

Boiler Cycles

Boiler Cycles/Hours

Run Time Hours

Data Logging

Real time graphic trends allow users to observe process

changes over time providing valuable diagnostic

information. For example, ame current performance

over start up periods and varying loads can be an indication

of gas supply issues. Additionally, supply and return

temperature dual pen trends brings a focused look at

heat exchanger and pump performance. For example,

studying a differential temperature trend may indicate

pump speed settings need to be changed.

Cycles and Hours

Boiler cycles and hours are used to monitor the

boilers overall compatibility to the heating load.

Excessive cycling compared to run time hours

may be an indication of pumping, boiler sizing or

adjustment issues.

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.

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:

The rate % value is equal to the actual fan speed

divided by the maximum fan speed.

Setpoint:

this is the active setpoint. This temperature is the

result of Outdoor Air Reset, Setback and Domestic

Hot Water (DHW) selections.

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.

Supply 180 F

180 F

Rate 0%

Status: Standby

Setpoint

Boiler 1

Priority: Central Heat

iActive

Fault Rate Limit:

The “ ”symbol appears to the right

of the Rate % when firing rate is

limited or overridden in any way.

During the start-up and shutdown

sequence it is normal for the rate to be

overridden by the purge and light-off

requirements. When a rate limit is the

result of boiler protection logic the

“” symbol blinks and becomes a

screen link

Supply:

measured supply water temperature. This is the

temperature being used to start/stop and fire boiler

when there is a call-for- heat.

X. Operation F. Viewing Boiler Status (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.

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.

1. Status Screens (continued)

Heat Demand

Central Heat On

Domestic Hot Water Off

Sequence Master Off

Frost Protection Off

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.

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.

Central Heat

On Point -7 F

Setpoint

Off Point +5 F

Firing Rate 22%

Setpoint: Outdoor Reset

180 F180 F

Supply

Outdoor Reset

Outside Air

180

130

110

0 70

Setpoint 164 F

Outside Air 16 F

Status: Enabled

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:

Header 132 F

180 F

Rate 100%

Networked Boilers:

Setpoint

Sequencer

Priority: Domestic Hot Water

1 ,2 ,3 ,4 ,5 ,6 ,7 ,8

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.

Rate:

The rate % value is equal to the

Sequence Master demand to the

individual boiler. Actual boiler firing

rate is found on the individual boiler

status pages.

Priority:

The selected Sequencer Priority is

shown. Available Priorities are:

Standby (no call for heat is present),

Central Heat, Domestic Hot Water,

Frost Protection or Warm Weather

Shutdown.

Networked Boiler Status:

Provides connected, start sequence and firing rate status information for all connected boiler addresses. The boiler number is

underlined if the boiler is running and blinks if the boiler has the start sequence in progress. For example the status for boiler

address 1 is provided as follows:

1 - Boiler 1 is connected to the network

1 - “Blinking underline” - boiler 1 is starting

1 - “Solid underline” - boiler 1 is running

Networked Boilers

Boiler 1 Lead 50% Firing

Boiler 2 50% Firing

Boiler 3 0 % Available

Boiler 4 0 % Available

The “Networked Boilers” screen is selected by “pressing” the “Detail” button from the “Home” screens and “pressing” Networked

Boilers” from the “Detail” screen.

Boiler Number:

Up to eight (8) boiler’s status is

shown

Lead Boiler:

Upon power up the lowest numbered

boiler becomes the lead boiler. The

lead boiler is the first to start and last

to stop. The lead boiler is

automatically rotated after 24 hours of

run time. Additionally, the lead is

rotated if there is a lead boiler fault.

Firing Rate:

Demanded firing rate is

provided.

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.

X. Operation G. Changing Adjustable Parameters (continued)

1. Entering Adjust Mode

The Control is factory programmed

to include basic modulating boiler

functionality. These settings are password

protected to discourage unauthorized or

accidental changes to settings. User login is

required to view or adjust these settings:

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

screen.

- Press the “Adjust” button on the Adjust

Mode screen or Press 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.

G. Changing Adjustable Parameters

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

1CL

5432

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

Figure 56: Adjust Mode Screens

2. Adjusting Parameters

Editing parameters is accomplished as follows:

Value to be edited

(blinks while editing)

Edit Value

Press the buttons to edit a

value. While editing a value it will blink

until it has been accepted or cancelled. A

value is also cancelled by leaving the

screen without accepting the value.

Cancel edit

Press the button to cancel

newly edited value and go back

to the original

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

CH Setpoint

Central Heat

180 F

X. Operation G. Changing Adjustable Parameters (continued)

2. Adjusting Parameters (continued)

From the “Home” screen select the Adjust button to access the adjustment mode screens 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

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

“Press”

System

Setup

button to access the following parameters:

Factory

Setting

Range /

Choices Parameter and Description

Fahrenheit Fahrenheit,

Celsius

Temperature Units

The Temperature Units parameter determines whether temperature is represented in units of

Fahrenheit or Celsius degrees.

4 0-14 Display Brightness

Display brightness is adjustable from 0 to 14.

8 0-14 Display Contrast

Display contrast is adjustable from 0 to 14.

Wired

Not Installed,

Wired

Wireless

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.

Enabled Enable/Disable

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:

0 Secs 0-900 Secs

Anti-Short Cycle Time

Anti-short cycle is a tool that helps prevent excessive cycling resulting from a fast cycling

Thermostat or Zone valves. It provides a minimum delay time before the next burner cycle. DHW

demand is serviced immediately, without any delay.

Disabled Enable/Disable

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.

70°F 0-100°F

Warm Weather Shutdown Setpoint

The Warm Weather Shutdown (WWSD) Setpoint used to shutdown the boiler when enabled by the

“WWSD Enable” parameter.

Device

Started

Start

Temperatures

Stop

Temperatures

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

X. Operation G. Changing Adjustable 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.

2. Adjusting Parameters (continued)

“Press”

Modulation

Setup

button to access the following parameters:

Factory

Setting

Range /

Choices Parameter and Description

See Table

30 See Table 30

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.

See Table

Minimum to

Maximum

Modulation

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.

See Table

Minimum to

Maximum

Modulation

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.

See Table

Minimum

- 100 to

Maximum

Minimum Modulation

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

See Table

2500 - Maximum

Light-off Rate

Lightoff Rate

This is the blower speed during ignition and ame stabilization periods.

Spare Part:

Sage2.1 Controller - P/N 104471-01

Maximum Light-off Rate

= 4000

Sage2.1 Controller - P/N 104471-04

Maximum Light-off Rate

= 4000

Altitude 0 -7000 ft. 0 - 5000 ft.

Boiler Type 399

-07

500

-07

800N

-05

800P

-05

Maximum Modulation Rate 7600 5900 5200 5150

Minimum Modulation Rate 2100 1400 1200 1200

Absolute Maximum Modulation Rate 8500 6550 5900 5600

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

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.

X. Operation G. Changing Adjustable Parameters (continued)

“Press”

Pump Setup

button to access the following parameters:

Factory Setting Range / Choices Parameter and Description

Central Heat,

Optional Priority

Never,

Any Demand,

Central heat, No Priority,

Central Heat, Optional

Priority

System Pump run pump for:

Activates the system pump output according to selected function.

Never: Pump is disabled and not shown on status screen.

Any Demand: Pump Runs during any call for heat.

Central Heat, No Priority: Pump Runs during central heat and frost

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.

Any Demand Any Demand,

Central heat, off DHW

demand

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.

Primary

Loop Pipe

IWH

Never,

Primary Loop Piped IWH,

Boiler Piped IWH

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).

Explanation:

This piping arrangement only services

central heat. When there is any de-

mand both boiler and system pumps

turn on.

Parameter Selections:

System Pump= “any demand”

Boiler Pump = “any demand”

DHW Pump = “never”

Example Pump Parameter selections:

Single boiler with no Indirect Water Heater

X. Operation G. Changing Adjustable Parameters (continued)

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.

Example Pump Parameter selections (continued):

Single boiler Indirect Water Heater Piped to Primary, Optional Domestic Hot Water Priority.

Multiple Boilers with Boiler Piped IWH, System and DHW Wired to Master

Sequencer Master

(Boiler 1) Boiler 2

Wiring locations:

Thermostat X

DHW call for heat X

System pump X

DHW pump X

Boiler Pump X X

Sequencer Master Parameter Selections:

Sequencer Master Enabled

Indirect Water

Heater “Boiler Piped”

Pump Parameter Selections:

System Pump = Central Heat,

No Priority Never

Boiler Pump = Central Heat,

Off DHW Priority

Any

demand

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.

X. Operation G. Changing Adjustable Parameters (continued)

Multiple boilers IWH Piped to Primary, Optional Domestic Hot Water Priority

Sequencer Master

(Boiler 1) Boiler 2

Wiring locations:

Thermostat X

DHW call for heat X

System pump X

DHW pump X

Boiler Pump X X

Sequencer Master Parameter Selections:

Sequencer Master Enabled

Indirect Water

Heater “Primary Piped”

Pump Parameter Selections:

System Pump = Central Heat,

Optional Priority Never

Boiler Pump = Any demand Any

demand

DHW Pump = Primary Loop

Piped IWH Never

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.

Example Pump Parameter selections (continued):

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

Sequencer Master

(Boiler 1) Boiler 2

Wiring locations:

Thermostat X

DHW call for heat X

System pump X

DHW pump X

Boiler Pump X X

Sequencer Master Parameter Selections:

Sequencer Master Enabled

Indirect Water

Heater “Primary Piped”

Pump Parameter Selections:

System Pump = Any demand Never

Boiler Pump = Any demand Any demand

DHW Pump = Primary Loop

Piped IWH Never

Explanation:

This piping arrangement requires the system pump to be running for any calls for heat. Also the boiler pump must run for any

call for heat.

X. Operation G. Changing Adjustable Parameters (continued)

“Press”

Contractor

Setup

button to access the following parameters:

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

“Press”

Manual

Control

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.

Status Auto

0 RPM 0%

press to change mode

High Auto

Low

NOTE

Selecting “Low” or “High”

locks (manual mode) firing

rate at min or max Rate %.

After combustion testing select

“Auto” to return the boiler to

normal operation.

Press “Auto”

to return

firing rate to

Automatic

Mode

“Press” “Low” to select

manual firing rate control

and Minimum firing rate %

Manual Speed Control

“Press” “High” to select

manual firing rate control

and Central Heat

Maximum firing rate %

Use Up and DOWN Arrows for More

Exit Screen without Saving

Clear Entire Field

Backspace

Save Field and Exit

Save

Press box to input contractor information.

Contractor Name

Bill Smith

AES

Enter Contractor Information

Bill Smith

Press SAVE button to store revisions.

For Service Contact:

Bill Smith

12 Victory Lane

Plainview, New York

516 123-4567

Example Screen

X. Operation G. Changing Adjustable Parameters (continued)

“Press”

Domestic

Hot Water

button to access the following parameters:

Factory

Setting

Range /

Choices Parameter and Description

170°F 80°F to

190°F

Domestic Hot Water Setpoint

The Domestic Hot Water (DHW) Setpoint parameter is used to create a minimum boiler water tem-

perature setpoint that is used when DHW heat demand is “on”.

When the DHW heat demand is not “on” (the contact is open or not wired) this setpoint is ignored.

160°F 80°F to

190°F

Domestic Hot Water 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 DHW setpoint to lower the DHW temperature and to save energy while home is in a reduced

room temperature mode.

5°F 2°F to 10°F Domestic Hot Water Diff Above

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

7°F 2°F to 30°F Domestic Hot Water Diff Below

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

Enable Enable

Disable

Domestic Hot Water Priority (DHWP)

When Domestic Hot Water Priority is Enabled and Domestic Hot Water (DHW) heat demand is “on”

the DHW demand will take “Priority” over home heating demand. When the System and Boiler pumps

are 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.

Minutes

30 to 120

Minutes

Priority Time

When DHWP is Enabled the Priority Time Parameter appears and is adjustable.

3 1 to 5

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.

“Press”

Central

Heat button to access the following parameters:

Factory

Setting

Range /

Choices Parameter and Description

180°F 80°F to

190°F

Central Heat Setpoint

Target temperature for the central heat priority. Value also used by the outdoor air reset function.

170°F 80°F to

190°F

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.

5°F 2°F to 10°F Central Heat Diff Above

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

7°F 2°F to 30°F Central Heat Diff Below

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

3 1 to 5

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.

X. Operation G. Changing Adjustable Parameters (continued)

“Press”

Outdoor

Reset

button to access the following parameters:

Factory

Setting

Range /

Choices Parameter and Description

Enabled Enable Disable

Outdoor Reset Enable

If an outdoor sensor is installed and Outdoor Reset is Enabled, the boiler will automatically

adjust the heating zone set point temperature based on the outdoor reset curve in Figure 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.

0°F -40°F to 100°F

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.

70°F 32°F to 100°F

High Outdoor Temperature

The High Outdoor Temperature parameter is the outdoor temperature at which the Low

Boiler Water Temperature is supplied. This parameter is typically set to the desired building

temperature.

110°F 70°F to 190°F

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.

130°F 80°F to 190°F

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.

0 Minutes

0-1800 Seconds

(0-30 Minutes)

Boost Time

When the Central Heat Setpoint is decreased by Outdoor Reset settings, the Boost Time

parameter is used to increase the operating setpoint when the home heat demand is not

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)

Central Heat

Setpoint Heating Element Type Central Heat

Setpoint Heating Element Type

180 to 190°F Fan Coil 100 to 140°F In Slab Radiant High

Mass Radiant

160 to 190°F

Convection

Baseboard

Fin Tube

Convective

130 to 160°F Staple-up Radiant

Low Mass Radiant

130 to 160°F Radiant

Baseboard 140 to 160°F Radiators

Figure 57: Outdoor Reset Curve

Outdoor Air Temperature

-20 105-15 -10 -5

110

454020 25 30 35 55 60 65 70

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)

100

X. Operation G. Changing Adjustable Parameters (continued)

Factory

Setting

Range /

Choices Parameter and Description

Local Local,

4-20mA

Central Heat Modulation Source

This parameter enables the 4-20mA input to control ring rate and the thermostat input to control boiler on/off

demand directly without using the internal setpoint. The 4-20mA selection is used to enable a remote multiple boiler

controller to control the Sage2.1 Control:

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

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

Local Local,

4-20mA

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.

130°F

80°F -

Central Heat

Setpoint

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).

180°F

80°F -

Central Heat

Setpoint

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).

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

“Press”

Remote

4-20mA

button to access the following parameters:

“Press”

Sequence

Master

button to access the following parameters:

Factory

Setting Range / Choices Parameter and Description

Disable Enable,

Disable

Master Enable/Disable

The Sequencer Master Enable/Disable is used to “turn on” the Multiple Boiler Controller. Warning! enable

ONLY one Sequence Master.

Boiler

Piped

Boiler Piped,

Primary Piped

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.

Disabled Enable,

Disable

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.

120 Secs 120 - 1200 Secs

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.

195°F

Central Heat

Setpoint,

195°F

Stop All Boilers Setpoint

When this temperature is reached all boilers are stopped. This setpoint allows the Sequencer to respond to

rapid load increases.

50% 50% - 100%

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%.

3 1-5

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.

“Press”

Sequence

Slave

button to access the following parameters:

Factory

Setting Range / Choices Parameter and Description

None 1-8

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.

Normal

Use Boiler First,

Normal,

Use Boiler Last

Slave Selection Order

“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.

101

XI. Service and Maintenance

NOTICE

Warranty does not cover boiler damage or

malfunction if the following steps are not

performed at the intervals specied.

A. Continuously:

1. Keep the area around the boiler free from

combustible materials, gasoline and other ammable

vapors and liquids.

2. Keep the area around the combustion air inlet

terminal free from contaminates .

3. Keep the boiler room ventilation openings open and

unobstructed.

B. Monthly Inspections:

1. Inspect the vent piping and outside air intake piping

to verify they are open, unobstructed and free from

leakage or deterioration. Call the service technician

to make repairs if needed.

2. Inspect the condensate drain system to verify it is

leak tight, open and unobstructed. Call the service

technician if the condensate drain system requires

maintenance.

3. Inspect the ue temperature sensor cap to verify that

it is free from leakage and deterioration. Call the

Service Technician to make repairs, if needed.

4. Inspect the water and gas lines to verify they are

free from leaks. Call the service technician to make

repairs if required.

CAUTION

Water leaks can cause severe corrosion damage

to the boiler or other system components.

Immediately repair any leaks found.

C. Annual Inspections and Service: In addition to

the inspections listed above the following should be

performed by a service technician once every year.

1. If equipped, test the low water cutoff by pressing the

“Test” button located at its end. The yellow light

should come on and “Limit Open” will ash in the

Active Faults screen on the display. Push the reset

button to restore normal operation. If yellow light

does not come on, determine why the low water

cutoff is not working properly.

2. Follow the procedure for turning the boiler off per

Figure 51 “Lighting Instructions”.

3. Inspect the wiring to verify the conductors are in

good condition and attached securely.

DANGER

This boiler uses ammable gas, high voltage electricity, moving parts, and very hot water under high

pressure. Assure that all gas and electric power supplies are off and that the water temperature is cool

before attempting any disassembly or service.

Do not attempt any service work if gas is present in the air in the vicinity of the boiler. Never modify,

remove or tamper with any control device.

WARNING

This boiler must only be serviced and repaired by skilled and experienced service technicians.

If any controls are replaced, they must be replaced with identical models.

Read, understand and follow all the instructions and warnings contained in all the sections of this

manual.

If any electrical wires are disconnected during service, clearly label the wires and assure that the wires

are reconnected properly.

Never jump out or bypass any safety or operating control or component of this boiler.

Read, understand and follow all the instructions and warnings contained in ALL of the component

instruction manuals.

Assure that all safety and operating controls and components are operating properly before placing

the boiler back in service.

Annually inspect all vent gaskets and replace any exhibiting damage or deterioration.

102

CAUTION

Label all wires prior to disconnection when

servicing controls. Wiring errors can cause

improper and dangerous operation. Verify

proper operation after servicing.

4. Remove the igniter assembly and ame sensor and

inspect them for oxide deposits. Clean the oxide deposits

from the igniter electrodes and ame sensor rod with

steel wool. Do not use sandpaper for the cleaning.

Inspect the ceramic insulators for cracks and replace

the igniter assembly and/or ame sensor if necessary.

Check the igniter electrode spacing gap. Refer to Figure

58 “Igniter Electrode Gap” for details.

If the condensate neutralizer is used, check pH before

and after the neutralizer to determine neutralizing

effectiveness. Replace limestone chips and clean out

the neutralizer if needed.

10. Inspect the ue temperature sensor cap to verify that

it is free from leakage and deterioration, replace, if

needed.

11. Inspect vent connections and vent connector to heat

exchanger seals to verify that they are free from leakage

and deterioration, repair as needed.

12. Reinstall the gas valve/blower/burner assembly and

secure with M6X1 hex ange nuts.

13. Reconnect any wiring which has been disconnected.

14. Inspect the heating system and correct any other

deciencies prior to restarting the boiler.

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

installation.

16. Perform the combustion test outlined in Section IX

“System Start-up”.

17. Verify that the system PH is between 7.5 and 9.5.

18. Check for vent terminal obstructions and clean as

necessary.

D. Recommended Heating System Water Treatment

Products:

1. System Cleaning and Conditioning:

a. The following heating system water treatment

products are recommended for an initial existing

heating system sludge removal, initial boiler

cleaning from copper dust, ux residue and any

boiler debris and for preventive treatment as

corrosion/scale inhibitors:

i. Fernox™ Restorer (universal cleaner, sludge

remover, scale remover, ux residue/debris

remover, corrosion inhibitor)

ii. Fernox™ Protector (Alphi 11, CH#, Copal)

(sludge remover, corrosion inhibitor)

Follow manufacturer application procedure

for proper heating system/boiler cleaning and

preventive treatment.

Above referenced products are available

from Cookson Electronics Company, 4100

Sixth Avenue, Altoona, PA 16602, Tel: (814)

946-1611 and/or selected HVAC distributors.

Contact Burnham Commercial for specic

details.

iii. Equivalent system water treatment products

may be used in lieu of products referenced

above.

2. System Freeze Protection:

a. The following heating system freeze protection

products are recommended for Apex boilers:

Figure 58: Igniter Electrode Gap

5. To gain access to boiler burner and combustion chamber

rstly disconnect and remove gas inlet piping from

gas valve, than, remove six M6X1 hex ange nuts and

take out the blower/gas valve/burner assembly from

the boiler.

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

signicant lint and dust accumulations are found,

disassemble the blower/gas valve assembly to expose the

swirl plate and blower inlet (see the exploded diagram

in the parts list at the back of this manual). Vacuum

these parts as required, being careful not to damage

the vanes on the swirl plate.

7. Vacuum any dust or lint from the burner if present. If

the burner shows any visual deterioration or corrosion

signs, replace it immediately. Inspect the burner gasket

and replace, if necessary.

8. Inspect the heat exchanger combustion chamber, clean

and vacuum any debris found on the surfaces. If

required, brush the coils of the heat exchanger using

a non-metal wire exible brush. Any cleaning of the

combustion chamber with acid or alkali products

is prohibited. Remove insulation disc and clean the

surfaces by ushing with clean water. If the disc has

signs of damage, it must be replaced. Drain and ush the

inside of the heat exchanger and condensate collector.

Do not use any cleaning agents or solvents. Re-install

insulation disc upon cleaning completion..

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

from debris. Inspect condensate line integrity between

boiler and condensate neutralizer (if used), condensate

neutralizer and the drain. Clean/repair if needed.

XI. Service and Maintenance (continued)

103

i. Fernox™ Protector Alphi 11 (combined

antifreeze and inhibitor).

Follow manufacturer application procedure

to insure proper antifreeze concentration and

inhibitor level.

Above referenced product is available from

Cookson Electronics Company, 4100 Sixth

Avenue, Altoona, PA 16602, Tel: (814) 946-

1611 and/or selected HVAC distributors.

Contact Burnham Commercial for specic

details.

b. Equivalent system freeze protection products

may be used in lieu of product referenced above.

In general, freeze protection for new or existing

systems must use specially formulated glycol,

which contains inhibitors, preventing the glycol

from attacking the metallic system components.

Insure that system uid contains proper glycol

concentration and inhibitor level. The system should

be tested at least once a year and as recommended by

the manufacturer of the glycol solution. Allowance

should be made for expansion of the glycol solution.

CAUTION

Use only inhibited propylene glycol solutions

specically formulated for hydronic systems.

Do not use ethylene glycol, which is toxic and

can attack gaskets and seals used in hydronic

systems.

E. Condensate Overow Switch and Condensate Trap

Removal and Replacement:

For removal or replacement of the condensate overow

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

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

1. Condensate Overflow Switch Removal and

Replacement:

a. Disconnect power supply to boiler.

b. Remove two (2) wire nuts and disconnect overow

switch wire pigtails from boiler wiring.

c. Using pliers, release spring clip securing the

overow switch to condensate trap body and remove

the switch. Note that the switch has factory applied

silicon adhesive seal, which may have to be carefully

cut all around to facilitate the switch removal.

d. Insure the trap overow switch port is not obstructed

with silicon seal debris, clean as needed.

e. Apply silicon seal to the replacement switch

threads and install the switch into the trap body

making sure it is properly oriented - the arrow

molded into the switch hex end side must face

down for proper switch operation. See Figure

59 “Condensate Overow Switch Orientation”

for details.

f. Reconnect the switch wire pigtails to the boiler

wiring and secure with wire nuts.

g. Restore power supply to boiler. Fill up the trap

(see Section V “Condensate Disposal”) and verify

the switch operation.

2. Condensate Trap Removal and Reinstallation:

a. Disconnect power supply to boiler.

b. Remove two (2) wire nuts and disconnect overow

switch wire pigtails from boiler wiring.

c. Disconnect pressure switch hose from condensate

trap.

d. Disconnect outside condensate compression tting

from condensate trap stab.

XI. Service and Maintenance (continued)

Figure 59: Condensate Overow Switch Orientation

104

XI. Service and Maintenance (continued)

Outdoor Temperature Ohms of

Resistance

°F °C

-20 -28.9 106926

-10 -23.3 80485

0 -17.8 61246

10 -12.2 47092

20 -6.7 36519

30 -1.1 28558

40 4.4 22537

50 10.0 17926

60 15.6 14356

70 21.1 11578

76 24.4 10210

78 25.6 9795

80 26.7 9398

90 32.2 7672

100 37.8 6301

110 43.3 5203

120 48.9 4317

Outdoor Air Temperature Sensor

Temperature versus Resistance

(P/N 102946-01)

(10kOhm NTC Sensor)

Temperature Ohms of

Resistance

°F °C

32 0 36100

50 10 22790

68 20 14770

77 25 12000

86 30 9810

104 40 6653

122 50 4610

140 60 3250

158 70 2340

176 80 1710

194 90 1270

212 100 950

230 110 730

248 120 560

Supply, Return and Stack Temperature Sensor

Temperature versus Resistance

(12kOhm NTC Sensor), Beta of 3750

Header Temperature Sensor

Temperature versus Resistance

(P/N 101935-01 or 103104-01)

(10kOhm NTC Sensor), Beta of 3950

Temperature Ohms of

Resistance

°F °C

32 0 32648

50 10 19898

68 20 12492

77 25 10000

86 30 8057

104 40 5327

122 50 3602

140 60 2488

158 70 1752

176 80 1256

194 90 916

212 100 697

248 120 386

e. Using pliers, release spring clip securing the

overow switch to condensate trap body and remove

the switch. Note that the switch has factory applied

silicon adhesive seal, which may have to be carefully

cut all around to facilitate the switch removal.

f. Using pliers, release spring clip securing condensate

trap body to the heat exchanger bottom drain stab.

g. Firstly, pull the trap downwards to release from

the heat exchanger bottom drain stab; secondly,

pull the trap end from left side jacket panel sealing

grommet and remove the trap from boiler.

h. To reinstall the trap, reverse above steps.

i. If the original condensate overow switch is to

be re-used, follow the appropriate switch removal

steps from Condensate Overow Switch Removal

and Replacement procedure above.

j. Insure that fresh silicon sealant is applied to

the overow switch threads, and the switch is

properly oriented relative to the trap body -

the arrow molded into the switch hex side end

must face down for proper switch operation.

See Figure 59 “Condensate Overow Switch

Orientation” for details. Insure that pressure

switch hose is reconnected to the trap.

k. Restore power supply to boiler. Fill up the trap

(see Section V “Condensate Disposal”) and

verify the switch operation.

105

XII. Troubleshooting

WARNING

Turn off power to boiler before working on wiring.

Condition Possible Cause

Boiler not responding to call for heat, “Status” and

“Priority” show “Standby”.

Boiler is not seeing call for heat. Check thermostat or zone wiring for loose connection,

miswiring, or defective thermostat/zone control.

Boiler not responding to a call for heat, “Status”

shows “Standby” and “Priority” shows Central Heat

or Domestic Hot Water.

Boiler is not ring, temperature is greater than setpoint.

Boiler Running but System or Boiler Circulator is

not running

• Check wiring for loose connection, miswiring

• When there is a Domestic Hot Water Heat Request the System or Boiler pumps will be

forced “off” when there “Run Pump for” parameter is set to “Central heat, off DHW

demand” or “Central Heat, Optional Priority”. This has been set to allow all of the heat

to be provided for fast indirect water heater recovery. After one hour of “priority

protection” or the end of the Domestic Hot Water Heat Request the system and boiler

pumps will be free to run.

Home is cold during mild weather days • Increase Low Boiler Water Temperature parameter 5°F per day.

Home is cold during cold weather days • Increase High Boiler Water Temperature parameter 5°F per day

A. Troubleshooting problems where no error code is displayed.

Faults are investigated by selecting the “Help” button from the “Home” screen. When a fault is active the “Help”

button ashes and the home screen turns a red color. Continue to select ashing buttons to be directed to the Fault

cause.

B. Display Faults:

Boiler

Energy Save On

Max Efficiency On

Standby

iStatus

Help

Adjust

Detail

Lockout

History

Service

Contract

Boiler Size

Setup

Sequencer

Setup

Active Faults

**00FF Communication

Fault

Limit String

Status

Rate Limit

Status Reset

Sensor

Status

Soft Lockout

(Hold)

Hard

Lockout

024 F

Sensor

Fault

Help Screen Active Fault Screen

Home Screen

Figure 60: Help Menu

Indication Condition Possible Cause

Display Completely Dark

Fan off, LWCO lights off, no green power

light on Control

No 120Vac Power

at Boiler

Check breaker and wiring between breaker panel and boiler.

Display Completely Dark, Fan running No 24Vac

Power to Control

- Loose 120Vac connection wiring between boiler J-Box and transformer

- Loose 24 Vac connection wiring between transformer and Control.

Blinking Green power light on Control Control

Fault

- The green light is connected to internal power supply. The power supply

is repeatedly starting and stopping (not normal) making the light ash. The

microprocessors are not running.

- Try disconnecting all terminals except 24VAC to power the Control. The

green light should be steady. If it is not then the control is defective. If

steady, start plugging in all the connectors while watching the green light.

When faulty wiring reconnected green light will begin to ash.

Display Completely Dark but Boiler res No 5 Vdc

Power to Display

- Loose 5 Vdc connection wiring between display and Control

- Defective display.

**00FF Display lost

communication

with control

- Loose or defective display harness

- Defective Display

- Defective Control

ER0011 Adjustment Mode

Password Timeout

- The Control and Display are NOT defective. The password has timed out.

Simply cycle power to the Display to restore operation.

106

XII. Troubleshooting (continued)

Indication Condition Possible Cause

Sequencer

Setup

Flashing

Sequencer

Setup

Fault

This alarm is active if the slave boiler has lost communication with the Sequence Master. Check

the following:

- RJ 45 peer-to-peer network disconnected

- Sequencer Master was Enabled and then Disabled

- Master’s Boiler has been powered down.

- To clear fault restore communication or cycle power

Boiler Size

Setup

Flashing

Boiler

Size

Fault

WARNING!

Boiler size setting may not match actual boiler size.

The Boiler size setting determines min, max and light-off blower speeds. Incorrect boiler size can

cause hazardous burner conditions and improper operation that may result in PROPERTY LOSS,

PHYSICAL INJURY, OR DEATH.

Refer to Page 92 for boiler size setting instructions.

C. Help Screen Faults

D. Help Screen Diagnostic Features

Indication Possible Cause

Lockout History is stored in a rst-in, rst-out basis. Each History le is stored with boiler run hour of when the

lockout occurred.

The “When happened” and “Current” provide:

- “Current” is the run hour and status the boiler just nished.

- “When happened” is the run hour and status when the lockout occurred.

For Service Contact:

CONTRACTOR NAME

CONTRACTOR ADDRESS 1

CONTRACTOR ADDRESS 2

PHONE NUMBER

The user is given the contact information of the responsible service provider. Refer to page 96 for data entry

instructions.

Supply High Limit

Lockout History 1 of 10 (newest)

Status

Run Time Hour

Running Lockout

50 50

When happened Current

Indication Condition Possible Cause

Limit String Status

Air

Press

Switch

Limit String Status

Auto

Reset

Hi Limit

Condensate

Float Switch

(& Thermal Link

on Size > 210)

(Gas Press Switch,

LWCO,

External Hi Limit

When provided)

Limit String

Fault

The Limit String Status screen shows the faulty safety limit. A contact icon, either “open” or

“closed”, graphically represents each safety limit. The “closed” contact icon is steady; the “open”

contact icon is blinking. For example, the screen shown to the left illustrates a “closed” Air

Pressure Switch contact and an “open’ Auto Reset High Limit contact. The Auto Reset High Limit

is causing the boiler to stop ring.

NOTE: Since the limit string items are wired in series, all limits downstream of the “open” limit will

also appear on the screen as “open” (blinking) icons regardless of whether or not they are actually

open.

Sensor Status

Supply Sensor 180 F Normal

Return Sensor 768 F Shorted

Stack Sensor 024 F Open

Outdoor Sensor 45 F Normal

Header Sensor None

4-20mA Input 4 mA Normal

Sensor

Fault

The Sensor Status screen shows the status of all sensors. Possible states include:

None: Feature requiring this sensor has not been selected.

Normal: Sensor is working normally.

Shorted: Sensor is shorted or is defective.

Open: There is a break in the wiring between the Control and the sensor or the sensor is

defective

Out of Range: Sensor is defective or is being subjected to electrical noise.

Unreliable: Sensor is defective or is being subjected to electrical noise.

When a sensor fails “opened” or “shorted” the value is changed to reverse video (background

black and value white) “024” or “768” respectively to indicate that there is a fault with the sensor.

Rate Limit

Active Rate Limiter:

Rate Limits

High Stack Temp Rate Limit

Active Rate Override:

Burner Control Rate Override

High Stack

Temperature

Rate Limit

The following messages appear when the ring rate is limited or reduced to help avoid a lockout.

Refer to lockout section for potential corrective action.

- High Stack Temperature Limit

- High Supply Temperature Limit

- High Differential Temperature Limit

The following messages appear as part of a normal start and stop sequence:

- Minimum Modulate (normal start/stop sequence)

- Forced Modulation (normal start/stop sequence)

- Burner Control Rate (normal start/stop sequence)

- Manual Firing Rate ( User selection)

E. Active Fault Screen Faults

107

XII. Troubleshooting (continued)

F. Troubleshooting problems where a Soft Lockout Code is displayed. When a soft lockout occurs, the boiler will shut

down, the display will turn red and the “Help” button will “blink”. Select the “blinking” “Help” button to determine the

cause of the soft lockout. The boiler will automatically restart once the condition that caused the lockout is corrected.

Soft Lockout Codes Displayed

Lockout

Number Condition Possible Cause

Anti Short Cycle

Minimum time between starts has not been reached.

Normal delay used to avoid excessive cycles.

Boiler Safety Limit

Open

Boiler Safety Limit wired to terminals J6-1, 2 or 3

OPEN:

• Condensate Trap Float Switch

contact open.

• Thermal Link Switch contact open.

• Burner Door Thermostat with manual reset

contact open.

• Air Pressure Switch contact open.

• Auto Reset High Limit contact open.

• Loose wiring to limit device.

• Auto Reset Supply high limit sensor detected temperature in excess of 200°F.

• Defective Auto Reset Supply High Limit Switch.

• Plugged Condensate Trap - also check to ensure boiler is level.

• Thermal Link Switch blown due to temperature rise above 604°F (318°C).

• Burner Door Thermostat with manual reset contact open due to temperature rise

above 500°F (260°C) - check the cause of overheating (burner door insulation, loose

mounting, etc.).

• Air Pressure Switch contact open - check for blocked vent.

• See possible causes for “Hard Lockout 4”.

NOTE

Block Vent Special Note

Before a call for heat the air pressure switch is closed. When there is a call for heat

with a blocked vent the air pressure switch will open (due to excessive pressure of the

blower against a blocked ue pipe) after the blower starts. The control stops the start

sequence and stops the blower. After the blower stops the pressure switch re-closes

and the cycle continues. The displays shows the cause of trip for only the time the

pressure switch is open.

Boiler Safety Limit

Open

Boiler Safety Limit, or External Limit wired to

terminals J5-1 OPEN:

• Jumper for External Limit wired to terminals 11

and 12 or device connected to it open.

• Jumper for Low Water Cutoff (LWCO) Switch or

device connected to it open.

• Jumper for Low Gas Pressure Switch or device

connected to it open.

• See possible causes for “Hard Lockout 4”.

• Loose wiring to limit device.

• External Limit defective or jumper not installed.

• Low Gas Pressure Switch contact open (if installed).

• LWCO switch not installed and jumper missing.

• If yellow light on LWCO is on, system is low on water.

• If neither yellow or green light is on, check LWCO harness.

Return sensor fault Shorted or open return temperature sensor. • Shorted or mis-wired return sensor wiring.

• Defective return sensor.

Supply sensor fault Shorted or open supply temperature sensor. • Shorted or mis-wired supply sensor wiring.

• Defective supply sensor.

DHW sensor fault

Shorted or open Domestic Hot Water (DHW)

temperature sensor.

• Shorted or mis-wired DHW sensor wiring.

• Defective DHW sensor.

Stack sensor fault Shorted or open ue gas (stack) temperature sensor. • Shorted or mis-wired stack sensor wiring.

• Defective stack sensor.

Ignition failure Flame failure after 5 tries to restart.

• No gas pressure.

• Gas pressure under minimum value shown on rating plate.

• Gas line not completely purged of air.

• Defective Electrode.

• Loose burner ground connection.

• Defective Ignition Cable.

• Defective gas valve (check for 24 Vac at harness during trial for ignition before

replacing valve).

• Air-fuel mixture out of adjustment - consult factory.

Flame rod

shorted to ground

Flame rod shorted to ground • Shorted or mis-wired ame rode wiring.

• Defective ame rod.

DT inlet/outlet high

Temperature rise between supply and return is too

high.

• Inadequate boiler water ow. Verify that circulator is operating and that circulator

and piping are sized per Section VI of this manual.

Return temp higher

than supply

The Control is reading a return sensor temperature

higher than the supply sensor temperature. Condition

must be present for at least 75 seconds for this error

code to appear.

• Flow through boiler reversed. Verify correct piping and circulator orientation.

• No boiler water ow. Verify that system is purged of air and that appropriate valves

are open.

• Sensor wiring reversed.

• Supply or return sensor defective.

Supply temp has risen

too quickly

Supply water temperature has risen too quickly.

• See possible causes for “Hard Lockout 4”.

• Inadequate boiler water ow.

• Verify that circulator is operating and that circulator and piping are sized per

Section VI of this manual.

Blower speed not

proved

Normal waiting for blower speed to match purge and

light-off setpoint.

108

XII. Troubleshooting (continued)

G. Troubleshooting problems where a Hard Lockout Code is displayed. When a hard lockout occurs, the boiler will shut

down, the display will turn red and the “Help” button will “blink”. Select the “blinking” “Help” button to determine the

cause of the Hard Lockout. Once the condition that caused the lockout is corrected, the boiler will need to be manually reset

using the Reset button on the “Active Fault” display or located on the Sage2.1 Control.

Lockout Number Condition Possible Cause

Supply high limit

Sage2.1 supply sensor detected

temperatures in excess of 210°F.

• Heating load at time of error was far below the minimum ring

rate of the boiler.

• Defective system circulator or no ow in primary loop.

• Defective boiler circulator or no ow in boiler loop.

• Control system miswired so that the boiler operation is

permitted when no zones are calling.

DHW high limit

Sage2.1 DHW sensor detected

temperatures in excess of Setpoint.

• DHW load at time of error was far below the minimum ring

rate of the boiler.

• Control system miswired so that boiler operation is permitted

when no DHW are calling.

Stack High limit

Sage2.1 Flue gas (Stack) sensor detected

temperatures in excess of 204°F.

• Heat exchanger needs to be cleaned.

• Boiler over-red.

• Air-fuel mixture out of adjustment - consult factory.

Flame detected out of sequence

A ame signal was present when there

should be no ame.

• Defective gas valve - make sure inlet pressure is below

maximum on rating plate before replacing valve.

Light off rate proving failed

Blower is not running at Light-off rate

when it should or blower speed signal not

being detected by Sage2.1.

• Loose connection in 120 VAC blower wiring.

• Loose or miswired blower speed harness.

• Defective blower

Purge rate proving failed

Blower is not running at Purge rate when

it should or blower speed signal not being

detected by Sage2.1.

• Loose connection in 120 VAC blower wiring.

• Loose or miswired blower speed harness.

• Defective blower

Invalid Safety Parameters

Unacceptable Sage2.1 control Safety

related parameter detected. Safety Parameter verication required. Contact factory.

Invalid Modulation Parameter

Unacceptable Sage2.1 control Modulation

related parameter detected. Reset the control.

Safety data verication needed

Safety related parameter change has

been detected and a verication has not

been completed.

Safety related Sage2.1 control parameter has been changed and

verication has not been performed.

24VAC voltage low/high

Sage2.1 control 24Vac control power is

high or low.

• Loose connection in 24Vac VAC power wiring.

• Loose or miswired 24Vac harness.

• Miswired wiring harness causing power supply short to

ground.

• Defective transformer.

• Transformer frequency, voltage and VA do not meet

specications.

Fuel Valve Error

Power detected at fuel valve output when

fuel valve should be off.

• Loose or defective gas valve harness. Check electrical

connections.

• Defective gas valve (check for 24 Vac at harness during trial

for ignition before replacing valve).

Hardware Fault Internal control failure. • Reset the control. If problem reoccurs, replace the Sage.

Internal Fault Internal control failure. • Reset the control. If problem reoccurs, replace the Sage.

Ignition failure

Model APX500 and APX800:

Flame failure after 1 try to restart.

• No gas pressure.

• Gas pressure under minimum value shown on rating plate.

• Gas line not completely purged of air.

• Defective Electrode.

• Loose burner ground connection.

• Defective Ignition Cable.

• Defective gas valve (check for 24 Vac at harness during trial

for ignition before replacing valve).

• Air-fuel mixture out of adjustment - consult factory.

Hard Lockout Codes Displayed

109

XIII. Repair Parts

All Apex™ Series Repair Parts may be obtained through your local Burnham Commercial Cast Iron

Wholesale distributor. Should you require assistance in locating a Burnham Commercial Cast Iron

distributor in your area, or have questions regarding the availability of Burnham Commercial Cast Iron

products or repair parts, please contact Burnham Commercial Cast Iron Customer Service at

(888) 791-3790 or Fax (877) 501-5211.

110

1P-3

1P-2

1P-1

XIII. Repair Parts (continued)

1C 1D

111

XIII. Repair Parts (continued)

Key

No. Description (Quantity) Part Number

APX399 APX500 APX800

1A Bare Heat Exchanger 101931-06 101931-07 103261-01

1B Burner Head Assembly 101933-06 101933-07 103108-01

1C Replacement Igniter Kit 103005-01 103005-02 103308-01

1D Replacement Flame Sensor Kit 103339-01 103310-01

1E Replacement Partially Assembled Burner Door 102696-01 104597-01

1F Air Vent Valve 101586-01

1G Water Temp Sensor (2) 101685-01

1H High Limit 101653-01

1J Gasket, Header (All Three) N/A

1K Gasket, Header, 1” NPT N/A

1L Gasket, Header, 1” & 3/4” NPT N/A

1M Gasket, Header, 1-1/2” NPT 101372-03

1N Gasket, Header, 3/4” NPT 101372-01

1P-1 Gas/Air Intake Duct Assembly 101725-02 N/A N/A

1P-2 Gas/Air Intake Duct Assembly N/A N/A 103338-01

1P-3 Gas/Air Intake Duct Weldment N/A 102615-01 N/A

1Q Burner Plate Insulation (Warning: Contains RCF, Not Shown) 101728-01 103610-01

1R Burner Plate Inner Seal 101729-01

1S Burner Plate Outer Seal 101730-01

1T Burner Head 101731-06 102658-01 104584-01

1U Burner Head Seal 101732-01

1V Insulation Disc (Warning: Contains RCF) 101996-02

1W Burner Door Thermostat with Manual Reset 104569-01

M6x1 Hex Flange Nut (Not Shown) (6) 101724-01

M5x14 mm Pan Hd Thread Forming Screw, T25 Drive (Not Shown) (4) 101742-01 N/A

M5x10mm Pan Hd Thread Forming Screw, Phillips Drive (Not Shown) N/A (5) 102671-01

Thermal Link Switch (Backside of Duo Heat Exchanger) (Not Shown) 103321-01

Flue Exit Gasket Kit (Inside of Vent Termination of Heat Exchanger),

(Not Shown) 104501-01 104502-01

112

XIII. Repair Parts (continued)

Key

No. Description (Quantity) Part Number

APX399 APX500 APX800

2A Blower 101530-01 101531-01 103222-01

Blower Inlet Shroud Assembly

(includes Gas Orice; Gas Orice O-Ring; (3x) M4x20 mm or (3x) M4x25 mm

Self-threading Screws; Injector Plate; (4x) M4 x 10 mm Flat Head Screws;

Air Intake Adapter - Air Connection Side; Swirlplate; (2x) M5 x 16 mm Phillips

Flat Head Screws; Blower Adapter Plate; Air Intake Adapter - Blower Side).

101704-04 101704-05 103223-01

2B-1 Blower Inlet Repair Kit (includes Blower Adapter Plate, Swirlplate and

Mounting Hardware) 104620-04 104620-05 N/A

2C Gas Valve 102975-06 102975-07

(2) 103224-01

(Nat. Gas)

103299-01 (LP)

2D Gas Valve Harness with Plug 102971-01 103300-01 (LP)

Gas Valve Harness with Two Plugs N/A 103225-01 (Nat. Gas)

2E Blower Outlet Gasket 101345-01 102614-01 103263-01

2F Gas Valve Flange Kit N/A 102972-03 (4) 102972-03

2G Rubber Grommet, Gas Line 101638-01 103252-01

APX800 Only

(SIZE 500)

(SIZE 399)

(SIZE 500 ONLY)

2B-1

APX399 and APX500 Only

113

Key

No. Description

(Quantity) Part Number

APX399 APX500 APX800

3A Low Gas Pressure Switch N/A 102702-01

3B High Gas Pressure Switch N/A 102703-01

3C Gas Pressure Switch Wire Harness N/A 102704-01

XIII. Repair Parts (continued)

114

Key

No. Description

(Quantity) Part Number

APX399 APX500 APX800

4A Air Pressure Switch 104426-01

4B Air Pressure Switch Tubing, Black 7016041 102770-01 103257-01

4C Condensate Trap, Blow Molded 101239-01

4D Blocked Condensate Drain Switch 101587-01

4E Spring Clip, Condensate Trap (2) 101632-01

4F Rubber Grommet, Condensate Trap 101595-01

4G Condensate Comp. Fitting 101546-01

XIII. Repair Parts (continued)

115

XIII. Repair Parts (continued)

Key

No. Description

(Quantity) Part Number

APX399 APX500 APX800

5A Sage2.1 (Programmed) 104472-01 104472-04

5B Programmed Display (with Mounting Hard-

ware) 104427-01

5C Transformer 102516-01 103193-01

116

XIII. Repair Parts (continued)

117

XIII. Repair Parts (continued)

Key

No. Description

(Quantity) Part Number

APX399 APX500 APX800

6A Jacket, Rear/Bottom Panel 103406-02 103407-01 N/A

6B Jacket, Left Side Panel 102776-06 102776-07 103232-01

6C Jacket, Right Side Panel 101766-02 102610-01 103233-01

6D Partition Shelf Assembly 102831-06 102831-07 103237-01

6E Jacket, Top Panel 101218-06 101218-07 103234-01

6F Heat Exchanger Support Assembly, Right Side 101232-06 101232-07 103228-01

6G Heat Exchanger Support, Left Side 101224-06 101224-07 103227-01

6H Bracket, High Voltage Terminal 102780-01

6J Bracket, Rear HX Support 101381-01

6K Jacket Support Bracket (2) 101593-01 (1) 101593-01 N/A

6L Lower Front Door Assembly 101227-02 101227-01

6M Jacket, Upper Front Panel 101509-01

6N Bracket, Right Clip 101508-01

6P Rubber Pad, Right Clip 101245-01

6R Draw Latch 101037-01

6S Bracket, Left Clip 101507-02 N/A

Bracket, HX Strap N/A 103229-01

6T Access Panel (5’ x 16’) N/A 102612-01 N/A

6U Gasket, Access Panel (5’ x 16’) N/A 102613-01 N/A

6V Bracket, Gas Train N/A 102611-01 103240-01

6W Gasket, Access Panel (5’ x 8’) (1) 102877-01 (2) 102877-01 (6) 102877-01

6X Jacket, Rear Panel N/A 103230-01

6Y Access Panel (5’ x 8’) (1) 102873-01 (2) 102873-01 (6) 102873-01

6Z Control, Slid Tray 102777-01 103336-01

6AA Gasket, Rear to Base & Partition N/A 103241-01

6BB Gasket, Rear to Side N/A 103242-01

6CC Gasket, Side to Base & Partition N/A 103243-01

6DD Gasket, Side to Base Support N/A 103244-01

6EE Gasket, Side to Header Strap N/A 103245-01

6FF Gasket, Side to HX Support N/A 103246-01

6GG Heat Exchanger Support, Front/Rear N/A 103231-01

6HH Base Pan N/A 102226-01

6JJ Bracket, Partition Shelf Support N/A 103239-01

Nylon Glide (4) 8186006 (6) 8186006

118

XIII. Repair Parts (continued)

119

XIII. Repair Parts (continued)

Key

No. Description

(Quantity) Part Number

APX399 APX500 APX800

6A Jacket, Rear/Bottom Panel 103406-02 103407-01 N/A

6B Jacket, Left Side Panel 102776-06 102776-07 103232-01

6C Jacket, Right Side Panel 102776-02 102610-01 103233-01

6D Partition Shelf Assembly 102831-06 102831-07 103237-01

6E Jacket, Top Panel 101218-06 101218-07 103234-01

6F Heat Exchanger Support Assembly, Right Side 101232-06 101232-07 103228-01

6G Heat Exchanger Support, Left Side 101224-06 101224-07 103227-01

6H Bracket, High Voltage Terminal 102780-01

6J Bracket, Rear HX Support 101381-01

6K Jacket Support Bracket (2) 101593-01 (1) 101593-01 N/A

6L Lower Front Door Assembly 101227-02 101227-01

6M Jacket, Upper Front Panel 101509-01

6N Bracket, Right Clip 101508-01

6P Rubber Pad, Right Clip 101245-01

6R Draw Latch 101037-01

6S Bracket, Left Clip 101507-02 N/A

Bracket, HX Strap N/A 103229-01

6T Access Panel (5’ x 16’) N/A 102612-01 N/A

6U Gasket, Access Panel (5’ x 16’) N/A 102613-01 N/A

6V Bracket, Gas Train N/A 102611-01 103240-01

6W Gasket, Access Panel (5’ x 8’) (1) 102877-01 (2) 102877-01 (6) 102877-01

6X Jacket, Rear Panel N/A 103230-01

6Y Access Panel (5’ x 8’) (1) 102873-01 (2) 102873-01 (6) 102873-01

6Z Control, Slid Tray 102777-01 103336-01

6AA Gasket, Rear to Base & Partition N/A 103241-01

6BB Gasket, Rear to Side N/A 103242-01

6CC Gasket, Side to Base & Partition N/A 103243-01

6DD Gasket, Side to Base Support N/A 103244-01

6EE Gasket, Side to Header Strap N/A 103245-01

6FF Gasket, Side to HX Support N/A 103246-01

6GG Heat Exchanger Support, Front/Rear N/A 103231-01

6HH Base Pan N/A 103226-01

6JJ Bracket, Partition Shelf Support N/A 103239-01

Nylon Glide (4) 8186006 (6) 8186006

120

Key

No. Vent System Components Part Number

(Quantity) Part Number

APX399 APX500 APX800

7A 4” Schedule 40 PVC Tee Vent/Combustion Air Terminal 102190-02 2 N/A

7B 4” Stainless Steel Rodent Screens 102191-02 2 N/A

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

7C 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 103268-02 N/A 1

6” Schedule 40 PVC 90° Elbow 103313-01 N/A 2

7E 8 oz. Bottle of Transition Cement 102195-01 1

7F 8 oz. Bottle of Primer 102194-01 1

7G 4” x 4” CPVC/PVC Vent System Connector 102183-03 1 N/A

6” x 6” CPVC/PVC Vent System Connector 103270-01 N/A 1

7H 4” x 4” CPVC/PVC Vent System Connector Gasket 102185-02 1 N/A

6” x 6” CPVC/PVC Vent System Connector Gasket 103248-01 N/A 1

7J Flue Temperature Sensor Cap 102153-01 1

Flue Temperature Sensor (Not Shown) 101687-01 1

XIII. Repair Parts (continued)

121

XIII. Repair Parts (continued)

Key

No. Description

(Quantity) Part Number

APX399 APX500 APX800

MISCELLANEOUS PARTS CARTON 102942-03 102942-03 102942-04

8A Temperature/Pressure Gauge 100282-01

8B External Gas Shut Off Valve 101615-01 816SOL0015

8C Relief Valve 81660302 81660375

8D Boiler Drain Valve 806603061

8E Boiler Stacking Brackets (2) 101679-01

8F Boiler Stacking Bracket Screws (8) 80860743

Outdoor Temperature Sensor (Not Shown) 102946-01

122

Key

No. Description Part Number

APX399 APX500 APX800

--- Complete Wiring Harness (includes 10A, 10B, 10C & 10D) 102701-02

10A Main (Low Voltage) Harness 103009-02

10B High Voltage Harness 103010-02

10C Blower Power Harness 103012-01

10D Communication Harness 103011-01

10E Igniter Harness 103486-01

10F Wiring Harness, Thermal Link and Burner Door Thermostat 104574-01

XIII. Repair Parts (continued)

123

Important Product Safety Information

Refractory Ceramic Fiber Product

Warning:

The Repair Parts list designates parts that contain refractory ceramic fibers

(RCF). RCF has been classified as a possible human carcinogen. When

exposed to temperatures about 1805°F, such as during direct flame contact,

RCF changes into crystalline silica, a known carcinogen. When disturbed as a

result of servicing or repair, these substances become airborne and, if inhaled,

may be hazardous to your health.

AVOID Breathing Fiber Particulates and Dust

Precautionary Measures:

Do not remove or replace RCF parts or attempt any service or repair work

involving RCF without wearing the following protective gear:

1. A National Institute for Occupational Safety and Health (NIOSH)

approved respirator

2. Long sleeved, loose fitting clothing

3. Gloves

4. Eye Protection

• Take steps to assure adequate ventilation.

• Wash all exposed body areas gently with soap and water after contact.

• Wash work clothes separately from other laundry and rinse washing

machine after use to avoid contaminating other clothes.

• Discard used RCF components by sealing in an airtight plastic bag. RCF

and crystalline silica are not classified as hazardous wastes in the United

States and Canada.

First Aid Procedures:

• If contact with eyes: Flush with water for at least 15 minutes. Seek

immediate medical attention if irritation persists.

• If contact with skin: Wash affected area gently with soap and water.

Seek immediate medical attention if irritation persists.

• If breathing difficulty develops: Leave the area and move to a location

with clean fresh air. Seek immediate medical attention if breathing

difficulties persist.

• Ingestion: Do not induce vomiting. Drink plenty of water. Seek

immediate medical attention.

124

Figure

Number

Page

Number Description

Section I - Product Description, Specications & Dimensional Data

Figure 1A 7 Model APX399

Figure 1B 8 Model APX500

Figure 1C 9 Model APX800

Section III - Pre-Installation and Boiler Mounting

Figure 2 12 Clearances To Combustible and Non-combustible Material

Figure 3 14 Stacking Boiler Attachment Bracket Placement

Section IV - Venting

Figure 4 17

Location of Vent Terminal Relative to Windows, Doors, Grades, Overhangs, Meters and Forced Air

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

Two-Pipe System Air Intake Terminal Not Shown)

Figure 5 20 Expansion Loop and Offset

Figure 6 21 Field Installation of CPVC/PVC Two-Pipe Vent System Connector

Figure 7 21 Near-Boiler Vent/Combustion Air Piping

Figure 8 23 Wall Penetration Clearances for PVC Vent Pipe

Figure 9A 23 Direct Vent - Sidewall Terminations

Figure 9B 24 Direct Vent - Sidewall Terminations (Optional)

Figure 10 24 Rodent Screen Installation

Figure 11 24 Direct Vent - Optional Sidewall Snorkel Terminations

Figure 12 25 Direct Vent - Vertical Terminations

Figure 13 26 Direct Vent - Vertical Terminations w/ Sloped Roof

Figure 14 28 Vent System Field Modication to Install PVC to PP Adapter (M&G/DuraVent Shown)

Figure 15 29 Flexible Vent in Masonry Chimney with Separate Air Intake

Figure 16 31 Field Installation of Two-Pipe Vent System Adapter for Stainless Steel

Figure 17 33 Field Installation of Boiler Concentric Vent Collar

Figure 18 33 Cut-To-Length Extension (Cuttable)

Figure 19 33 Fixed Extension (Non-Cuttable)

Figure 20 34 Cutting Straight Pipe

Figure 21 34 Joining Cuttable Pipe

Figure 22 34 Joining Non-Cuttable Pipe

Figure 23 35 Horizontal Concentric Venting

Figure 24 35 Dimension “L”

Figure 25 36 Cutting Vent Terminal Pipe

Figure 26 37 Completing Horizontal (Wall Terminal Installation)

Figure 27 37 Vertical Concentric Vent Installation

Figure 28 37 Dimension “H”

Figure 29 38 Cutting Vertical Terminal

Figure 30 38 Completing Vertical Terminal Installation

Figure 31 39 Chimney Chase Installation

Figure 32 41 Multiple Boiler Direct Vent Termination

Appendix A - Figures

125

Appendix A - Figures (continued)

Figure

Number

Page

Number Description

Section IV - Venting (continued)

Figure 33 42 Multiple Boiler Concentric Vent Termination

Section V - Condensate Disposal

Figure 34 44 Condensate Trap and Drain Line

Section VI - Water Piping and Trim

Figure 35 45 Factory Supplied Piping & Trim Installation

Figure 36 50 Near Boiler Piping - Heating Only

Figure 37 51 Near Boiler Piping - Heating Plus Indirect Water Heater

Figure 38A 52 Isolation of the Boiler From Oxygenated Water with A Plate Heat Exchanger

(IWH Piped as Part of Boiler Piping)

Figure 38B 53 Isolation of the Boiler From Oxygenated Water with A Plate Heat Exchanger

(IWH Piped Off System Header)

Figure 39A 54 Multiple Boiler Water Piping w/Domestic Hot Water Heater (Page 1 of 2)

Figure 39B 55 Multiple Boiler Water Piping w/Domestic Hot Water Heater (Page 2 of 2)

Figure 40A 56 Alternate Multiple Boiler Water Piping w/ Indirect Domestic Hot Water Heater (Page 1 of 2)

Figure 40B 57 Alternate Multiple Boiler Water Piping w/Indirect Domestic Hot Water Heater (Page 2 of 2)

Section VII - Gas Piping

Figure 41 61 Recommended Gas Piping

Figure 42 62 Gas Inlet Pressure Tap and Pressure Switch Location

Section VIII - Electrical

Figure 43 65 Ladder Diagram

Figure 44 66 & 67 Wiring Connections Diagram

Figure 45A 68 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

Figure 45B 69 Modied Wiring For DHW Priority When Using Low Flow Circulator Piped Off System Header -

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

Figure 46 70 Multiple Boiler Wiring Diagram, Internal Sage2.1 Multiple Boiler Control Sequencer (Three Boilers

Shown, Typical Connections for up to Eight Boilers)

Figure 47A 71 Multiple Boiler Wiring Diagram w/Tekmar 265 Control

Figure 47B 72 Multiple Boiler Wiring Diagram w/Tekmar 264 Control

Figure 48 73 Recommended Direct Immersion Header Sensor Installation Detail

Figure 49 73 Alternate “Immersion” type Header Sensor Installation Detail

Figure 50 74 RJ45 Splitter Installation Detail

Section IX- System Start-Up

Figure 51 76 Lighting Instructions

Figure 52 78 Burner Flame

Figure 53 79 Dungs Gas Valve Detail

126

Figure

Number

Page

Number Description

Section X - Operation

Figure 54 87 Status Screens

Figure 55 88 Detail Screens

Figure 56 90 Adjust Mode Screens

Figure 57 99 Outdoor Reset Curve

Section XI - Service and Maintenance

Figure 58 102 Igniter Electrode Gap

Figure 59 103 Condensate Overow Switch Orientation

Section XII - Troubleshooting

Figure 60 105 Help Menu

Section XIII - Repair Parts

N/A Pages 110 thru 122

Appendix A - Figures (continued)

127

Appendix B - Tables

Table

Number

Page

Number Description

Section I - Product Description, Specications & Dimensional Data

Table 1 6 Dimensional Data (See Figures 1A, 1B and 1C)

Table 2A 10 Rating Data - Models APX500 and APX800 (0 to 5000 Feet Elevation Above Sea Level)

Table 2B 10 Rating Data - Models APX500 and APX800 (5001 to 10000 Feet Elevation Above Sea Level)

Section III - Pre-Installation and Boiler Mounting

Table 3 13 Apex (APX) Boiler Model Stacking Combinations

Section IV - Venting

Table 4 16 Vent/Combustion Air System Options

Table 5A 18 CPVC/PVC Vent & Air Intake Components Included With Boiler

Table 5B 19 CPVC/PVC Vent & Air Intake Components (Installer Provided) required for Optional Horizontal

(Snorkel) Termination

Table 5C 19 CPVC/PVC Vent & Air Intake Components (Installer Provided) required for Optional Vertical (Roof)

Termination

Table 6 20 Vent System and Combustion Air System Components Equivalent Length vs. Component Nominal

Diameter

Table 7 20 Expansion Loop Lengths

Table 8 22 Vent/Combustion Air Pipe Length – Two-Pipe Direct Vent System Options (CPVC PVC and Stain-

less Steel/PVC or Galvanized Steel)

Table 9 27 Approved Polypropylene Pipe, Fittings and Terminations - M&G/DuraVent

Table 10 27 Approved Polypropylene Pipe, Fittings and Terminations - Centrotherm Eco

Table 11A 31 Burnham Commercial Vent System Components (Stainless Steel)

Table 11B 31 Alternate Vent Systems and Vent Components (Stainless Steel)

Table 12 32 Concentric Vent Length

Table 13 32 Concentric Vent Components (Applicable to APX500 Only)

Section VI - Water Piping and Trim

Table 14 46 Flow Range Requirement Through Boiler

Table 15 47 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

Table 16 49 Fitting & Valve Equivalent Length

Table 17 52 Multiple Boiler Water Manifold Sizing

Table 18 58

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

Section VII - Gas Piping

Table 19A 59 Maximum Capacity of Schedule 40 Black Pipe in CFH* (Natural Gas) For Gas Pressures of 0.5

psig or Less

Table 19B 60 Maximum Capacity of Schedule 40 Black Pipe in CFH* (LP Gas) For Gas Pressures of 0.5 psig or

Less

Table 20 60 Equivalent Length of Standard Pipe Fittings & Valves

Table 21 61 Specic Gravity Correction Factors

Table 22 61 Min./Max. Pressure Ratings

128

Table

Number

Page

Number Description

Section VIII - Electrical

Table 23 64 Boiler Current Draw

Section IX - System Start-Up

Table 24 78 Recommended Combustion Settings, Natural Gas

Table 25 79 Number of Clockwise Throttle Screw Turns for LP Conversion

Table 26 80 Recommended Combustion Settings, LP Gas

Section X - Operation

Table 27 82 Order of Priority

Table 28 83 Frost Protection

Table 29 85 Boiler Sequence of Operation

Table 30 92 Parameters Changed Using the Boiler Type Parameter Selections

Section XIII - Repair Parts

N/A Pages 111 thru 122

Appendix B - Tables (continued)

129

SERVICE RECORD

DATE SERVICE PERFORMED

130

SERVICE RECORD

DATE SERVICE PERFORMED

131

SERVICE RECORD

DATE SERVICE PERFORMED

132

Subject to the terms and conditions set forth below, Burnham Commercial, Lancaster,

Pennsylvania hereby extends the following limited warranties to the original owner of a

commercial grade water or steam boiler or Burnham Commercial supplied parts and/or

accessories manufactured and shipped on or after October 1, 2009:

ONE YEAR LIMITED WARRANTY ON COMMERCIAL GRADE BOILERS

AND PARTS / ACCESSORIES SUPPLIED BY BURNHAM COMMERCIAL.

Burnham Commercial warrants to the original owner that its commercial grade water

and steam boilers and parts/accessories comply at the time of manufacture with

recognized hydronic industry standards and requirements then in effect and will be

free of defects in material and workmanship under normal usage for a period of one

year from the date of original installation. If any part of a commercial grade boiler or

any part or accessory provided by Burnham Commercial is found to be defective in

material or workmanship during this one year period, Burnham Commercial will, at its

option, repair or replace the defective part (not including labor).

HEAT EXCHANGER WARRANTIES

Burnham Commercial warrants to the original owner that the heat exchanger of its

commercial grade boilers will remain free from defects in material and workmanship

under normal usage for the time period specified in the chart below to the original owner

at the original place of installation. If a claim is made under this warranty during the “No

Charge” period from the date of original installation, Burnham Commercial will, at its

option, repair or replace the heat exchanger (not including labor). If a claim is made

under this warranty after the expiration of the “No Charge” period from the date of

original installation, Burnham Commercial will, at its option and upon payment of the

pro-rated service charge set forth below, repair or replace the heat exchanger. The

service charge applicable to a heat exchanger warranty claim is based upon the number

of years the heat exchanger has been in service and will be determined as a percentage

of the retail price of the heat exchanger model involved at the time the warranty claim is

made as follows:

NOTE: If the heat exchanger involved is no longer available due to product obsolescence

or redesign, the value used to establish the retail price will be the published price as set

forth in Burnham Commercial Repair Parts Pricing where the heat exchanger last

appeared or the current retail price of the then nearest equivalent heat exchanger,

whichever is greater.

ADDITIONAL TERMS AND CONDITIONS

1. Applicability: The limited warranties set forth above are extended only to the

original owner at the original place of installation within the United States and

Canada. These warranties are applicable only to boilers, parts, or accessories

designated as commercial grade by Burnham Commercial and installed and

used exclusively for purposes of commercial space heating or domestic hot

water generation through a heat exchanger (or a combination for such purposes)

and do not apply to residential grade products or industrial uses.

2. Components Manufactured by Others: Upon expiration of the one year limited

warranty on commercial grade boilers, all boiler components other than heat

exchangers manufactured by others but furnished by Burnham Commercial

(such as oil burner, circulator and controls) will be subject only to the

manufacturer’s warranty, if any.

3. Proper Installation: The warranties extended by Burnham Commercial are

conditioned upon the installation of the commercial grade boiler, parts, and

accessories in strict compliance with Burnham Commercial installation

instructions. Burnham Commercial specifically disclaims liability of any kind

caused by or relating to improper installation.

4. Proper Use and Maintenance: The warranties extended by Burnham Commercial

conditioned upon the use of the commercial grade boiler, parts, and accessories

for its intended purposes and its maintenance accordance with Burnham

Commercial recommendations and hydronics industry standards. For proper

installation, use, and maintenance, see all applicable sections of the Installation

and Operating, and Service Instructions Manual furnished with the unit.

5. This warranty does not cover the following:

a. Expenses for removal or reinstallation. The owner will be responsible for

the cost of removing and reinstalling the alleged defective part or its

replacement and all labor and material connected therewith, and

transportation to and from Burnham Commercial.

b. Components that are part of the heating system but were not furnished by

Burnham Commercial as part of the commercial boiler.

c. Improper burner adjustment, control settings, care or maintenance.

d. This warranty cannot be considered as a guarantee of workmanship of an

installer connected with the installation of the Burnham Commercial boiler, or

as imposing on Burnham Commercial liability of any nature for unsatisfactory

performance as a result of faulty workmanship in the installation, which

liability is expressly disclaimed.

e. Boilers, parts, or accessories installed outside the 48 contiguous United

States, the State of Alaska and Canada.

f. Damage to the boiler and/or property due to installation or operation of the

boiler that is not in accordance with the boiler installation and operating

instruction manual.

g. Any damage or failure of the boiler resulting from hard water, scale buildup

or corrosion the heat exchanger.

h. Any damage caused by improper fuels, fuel additives or contaminated

combustion air that may cause fireside corrosion and/or clogging of the

burner or heat exchanger.

i. Any damage resulting from combustion air contaminated with particulate

which cause clogging of the burner or combustion chamber including but

not limited to sheetrock or plasterboard particles, dirt, and dust particulate.

j. Any damage, defects or malfunctions resulting from improper operation,

maintenance, misuse, abuse, accident, negligence including but not limited to

operation with insufficient water flow, improper water level, improper water

chemistry, or damage from freezing.

k. Any damage caused by water side clogging due to dirty systems or

corrosion products from the system.

l. Any damage resulting from natural disaster.

m. Damage or malfunction due to the lack of required maintenance outlined in

the Installation and Operating Manuals furnished with the unit.

6. Exclusive Remedy: Burnham Commercial obligation for any breach of these

warranties is limited to the repair or replacement of its parts (not including

labor) in accordance with the terms and conditions of these warranties.

7. Limitation of Damages: Under no circumstances shall Burnham Commercial be

liable for incidental, indirect, special or consequential damages of any kind

whatsoever under these warranties, including, but not limited to, injury or damage

to persons or property and damages for loss of use, inconvenience or loss of time.

Burnham Commercial liability under these warranties shall under no circumstances

exceed the purchase price paid by the owner for the commercial grade boiler

involved. Some states do not allow the exclusion or limitation of incidental or

consequential damages, so the above limitation or exclusion may not apply to you.

8. Limitation of Warranties: These warranties set forth the entire obligation of

Burnham Commercial with respect to any defect in a commercial grade boiler,

parts, or accessories and Burnham Commercial shall have no express obligations,

responsibilities or liabilities of any kind whatsoever other than those set forth

herein. These warranties are given in lieu of all other express warranties.

ALL APPLICABLE IMPLIED WARRANTIES, IF ANY, INCLUDING ANY

WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR

PURPOSE ARE EXPRESSLY LIMITED IN DURATION TO A PERIOD OF ONE

YEAR EXCEPT THAT IMPLIED WARRANTIES, IF ANY, APPLICABLE TO

THE HEAT EXCHANGER IN A COMMERCIAL GRADE BOILER SHALL

EXTEND TO THE ORIGINAL OWNER FOR THE TIME SPECIFIED IN THE

HEAT EXCHANGER SECTION SHOWN ABOVE AT THE ORIGINAL PLACE

OF INSTALLATION. SOME STATES DO NOT ALLOW LIMITATION ON HOW

LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY

NOT APPLY TO YOU.

PROCEDURE FOR OBTAINING WARRANTY SERVICE

In order to assure prompt warranty service, the owner is requested to complete

and mail the Warranty Card provided with the product or register product online

at www.burnhamcommercialcastiron.com within ten days after the installation of

the boiler, although failure to comply with this request will not void the owner’s

rights under these warranties. Upon discovery of a condition believed to be

related to a defect in material or workmanship covered by these warranties, the

owner should notify the installer, who will in turn notify the distributor. If this

action is not possible or does not produce a prompt response, the owner should

write to Burnham Commercial, P.O. Box 3939, Lancaster, PA 17604, giving full

particulars in support of the claim. The owner is required to make available for

inspection by Burnham Commercial or its representative the parts claimed to be

defective and, if requested by Burnham Commercial to ship these parts prepaid

to Burnham Commercial at the above address for inspection or repair. In

addition, the owner agrees to make all reasonable efforts to settle any

disagreement arising in connection with a claim before resorting to legal

remedies in the courts.

THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY

ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE.

Using Cast Iron, Carbon Steel,

or Stainless Steel Heat Exchangers

Years in Service 1 23456789 10+

Cast Iron 100

Carbon Steel No Charge

Stainless Steel 20 40 60 80 100

100

No Charge

Service Charge as a % of Retail Price

Burnham Commercial, P.O. Box 3939, Lancaster, PA 17604

Pub. No. BCL1109041 Revised November 1, 2009

Commercial Boilers

3 Form No. 188 - Effective 12/1/09

Burnham Apex Installation And Operation Manual

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