Page 1 Size Range - 80 MBH through 285 MBH 9700609 As an ENERGY STAR Partner, U.S. Boiler Company has determined that the Alpine™ Series meets the ENERGY ® STAR guidelines for energy efficiency established by the United States Environmental Protection Agency (EPA).
Page 2 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 Alpine™ 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.
Page 3 Special Installation Requirements for Massachusetts A. For all sidewall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes and where the sidewall exhaust vent termination is less than seven (7) feet above grade, the following requirements shall be satisfied: 1.
Page 4: Table Of Contents
TABLE OF CONTENTS Product Description, Specifications and Dimensional Data...... Unpacking Boiler..................III. Pre-Installation and Boiler Mounting ............Venting...................... A. General Guidelines................18 B. CPVC/PVC Venting................22 C. Polypropylene Venting................. 35 D. Stainless Steel Venting................ 43 E. Removing the Existing Boiler............... 48 F.
Page 5: I. Product Description, Specifications And Dimensional Data
I. Product Description, Specifications and Dimensional Data Alpine™ Series boilers are condensing high efficiency for Construction of Heating Boilers’ of ASME Boiler and gas-fired direct vent hot water heating boilers designed Pressure Vessel Code, which provide a maximum heat for use in forced hot water space or space heating with...
Page 6 103448-07- 1/16...
Page 7 103448-07 - 1/16...
Page 8 103448-07- 1/16...
Page 9: Ii. Unpacking Boiler
I. Product Description, Specifications and Dimensional Data (continued) Table 2: ratings alpine Series gas-Fired Boilers Input (MBH) Heating Capacity AFUE Net AHRI Ratings Water Model Number (MBH) (MBH) Min. Max. ALP080B ALP105B ALP150B ALP210B ALP285B Ratings shown are for installations at sea level and elevations up to 2000 ft. For elevations above 2000 ft., the boiler will naturally derate by 2.5% for each 1000 ft.
Page 10: Iii. Pre-Installation And Boiler Mounting
1. Alpine boilers are intended for installations ordinance. Refer to Figure 2A or 2B for minimum listed in an area with a floor drain or in a suitable drain clearances from combustible material.
Page 11 Boiler must be level to prevent condensate from boiler. backing up inside the boiler. 3. Alpine boilers must be installed level c. Provide adequate space for condensate piping or a condensate pump if required. prevent condensate from backing up inside the boiler.
Page 12 Top = 24 in. (610 mm), Front = 24 in. (610 mm), Left Side = 24 in. (610 mm), Right Side = 24 in. (610 mm), alpine boiler approximate dry weights: Rear = 24 in. (610 mm) aLP080BW – 98 lbs; aLP105BW – 112 lbs;...
Page 13 iii. Pre-installation and Boiler Mounting G. General (continued) c. 5/16 in. x 2 in. lag screws and 5/16 in. plated f. Once a suitable location has been selected for the washers are intended for mounting the boiler boiler, and any needed modifications have been directly onto studs covered with ½...
Page 14 iii. Pre-installation and Boiler Mounting G. General (continued) CaUTiOn CaUTiOn The outer edges of the template represent When positioning the template in the desired minimum side, top and bottom clearances to location on the wall insure that the minimum combustible material. if the template needs to be clearances to combustible material at adjacent cut to fit into a selected location, it would indicate walls and ceiling are maintained.
Page 15 Pre-installation and Boiler Mounting G. General (continued) b. Each Alpine 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.
Page 16 iii. Pre-installation and Boiler Mounting H. Boiler Stacking (continued) boiler flue gas condensate line construction and condensate disposal. Terminating individual Warning boiler condensate lines into common pipe prior to drain disposal is permissible, providing asphyxiation Hazard. no common manifold common pipe has sufficient flow capacity venting is permitted.
Page 17: Iv. Venting
iV. Venting Warning asphyxiation Hazard. Failure to vent this boiler in accordance with these instructions could cause products of combustion to enter the building resulting in severe property damage, personal injury or death. Do not use a barometric damper, draft hood or vent damper with this boiler. Do not locate vent termination under a deck.
Page 18: A. General Guidelines
If possible, slope horizontal combustion air pipe minimum 1/4 in/ft (21 mm/m) downward b. The Alpine is a Direct Vent (sealed combustion) towards terminal. If not, slope towards boiler. boiler. Combustion air must be supplied directly to the burner enclosure from outdoors and flue f.
Page 19 Venting A. General Guidelines (continued) iii. For Alpine boilers factory build prior to h. Locate bottom of vent terminal at least 7 ft. (2.1 January 2016, US Boiler provided PVC tees m) above a public walkway. (3” or 4” as applicable to specific boiler i.
Page 20 iV. Venting A. General Guidelines (continued) Table 4: Vent/Combustion air intake System Options Vent & intake Penetration Through Component reference Option Termination Figures Materials Structure Table Section Intake Horizontal Sidewall 90° Elbow w/ Screen 5, 6A, 6B 7A, 7B Vent Horizontal Sidewall Coupling w/ Screen Intake...
Page 21 2.5 (0.76) 60 (18.3) Diameter ALP105B Factory Build 3 (80) 2.5 (0.76) 135 (41.1) 3 (80) 2.5 (0.76) 135 (41.1) ALP150B Factory Build 3 (80) 2.5 (0.76) 135 (41.1) 3 (80) 2.5 (0.76) 100 (30.5) ALP210B Factory Build 3 (80) 2.5 (0.76)
Page 22: B. Cpvc/Pvc Venting
iV. Venting B. CPVC/PVC Venting Table 6: Vent/Combustion Air Equivalent Length Calculation Work Sheet Combustion air Vent Equivalent Equivalent Component Subtotal Subtotal Equivalent Length Per Quantity Length Quantity Equivalent Length Length Piece Per Piece Straight Pipe 90° Elbow, Short Radius 90°...
Page 23 iV. Venting B. CPVC/PVC Venting (continued) Figure 6B: Direct Vent - Snorkel Vent and air Figure 5: Direct Vent - Vent and air intake intake Horizontal Sidewall Terminations Horizontal Sidewall Terminations Figure 6C: Split rigid Vent Option Figure 6a: Direct Vent - Staggered Vent and air intake Horizontal Sidewall Terminations 103448-07 - 1/16...
Page 24 iV. Venting B. CPVC/PVC Venting (continued) PVC VENT PIPE CPVC VENT PIPE PITCH VENT PIPE 1/4" PER (FIRST 30" + ELBOW) FOOT TOWARDS BOILER PVC AIR INTAKE PIPE ALTERNATE ORIENTATION Figure 6D: Direct Vent - Horizontal Two-pipe Venting/Air Intake with IPEX Low Profile or DiversiTech HVEnT Terminal PITCH INTAKE AWAY FROM BUILDING EXTERIOR...
Page 25 iV. Venting B. CPVC/PVC Venting (continued) Figure 6H: Cutting iPEX FgV or DiversiTech CVEnT Concentric Terminal Figure 6J: Installation of IPEX FGV or DiversiTech CVENT Concentric Terminal thru Sidewall Figure 7a: Direct Vent - Vent and air intake Vertical Terminations with Flat roof 103448-07 - 1/16...
Page 26 iV. Venting B. CPVC/PVC Venting (continued) Figure 7B: Direct Vent - Vertical Two-Pipe Venting/air intake with iPEX FgV or DiversiTech CVEnT Concentric Terminal Figure 7C: installation of iPEX FgV or DiversiTech CVEnT Concentric Terminal thru roof 103448-07- 1/16...
Page 27 iV. Venting B. CPVC/PVC Venting (continued) Extend vent/combustion air piping to maintain minimum vertical (‘X’) and minimum horizontal (‘Y’) distance of 12 in. (300 mm) [18 in. (460 mm) Canada] from roof surface. allow additional vertical (‘X’) distance for expected snow accumulation. Figure 8: Direct Vent - Vent and air intake Vertical Terminations with Sloped roof Figure 9: Field installation of CPVC/PVC Two-Pipe Vent Connector with Factory installed Flue Temperature Sensor and Sensor Cap - Floor Mounted Boiler Builds...
Page 28 iV. Venting B. CPVC/PVC Venting (continued) Table 6a: Expansion Loop Lengths nominal Length of Loop Length Pipe Dia. Straight run “L” (in.) (in.) (Ft.) Figure 10B: Field installation of CPVC Vent Pipe - Wall Mounted Boiler Builds Figure 11: CPVC/PVC Expansion Loop and Offset 103448-07- 1/16...
Page 29 Venting B. CPVC/PVC Venting (continued) Table 7a: CPVC/PVC Vent & air intake Components included With Boiler Quantity aLP080B & aLP105B aLP150B & aLP210B aLP285B Part Standard Termination Standard Termination Standard Termination Vent & air intake Components number Vent Kit...
Page 30 B. CPVC/PVC Venting (continued) Table 7C: CPVC/PVC Vent & air intake Components (installer Provided for Optional Vertical (roof) Termination (applicable to Twin-Pipe Venting with Separate Vent & air intake roof Terminations) Quantity aLP080B & aLP150B & Part aLP285B Vent Components aLP105B...
Page 31 iV. Venting B. CPVC/PVC Venting (continued) 1. Components 3. Near-Boiler Vent/Combustion Air Piping Refer to Figure 10A and the following Steps: a. See Table 7A for CPVC/PVC vent and combustion air components included with boiler. a. Models ALP150BF thru ALP210BF (floor mounted) and ALP285B only: b.
Page 32 iV. Venting B. CPVC/PVC Venting (continued) d. Secure the pipe by tightening the metal strap PVC Pipe for PVC usage for venting limitation. worm screw. Thereafter, the balance of vent pipe up to vent termination can be done with PVC (ASTM 2665) pipe.
Page 33 iV. Venting B. CPVC/PVC Venting (continued) ii. Combustion Air Piping • Size combustion air pipe wall penetration opening to allow easy insertion of the pipe. • Install rodent screen and combustion air terminal (supplied with boiler). See Figure 13 for appropriate configuration details. •...
Page 34 iV. Venting B. CPVC/PVC Venting (continued) • Brace exterior piping if required. • Brace exterior piping if required. ii. Combustion Air Piping c. Optional Two-Pipe Termination into IPEX Low Profile or DiversiTech HVENT Terminal – • If possible, locate combustion air horizontal thru sidewall, see Figures 6D and 6F.
Page 35: C. Polypropylene Venting
iV. Venting C. Polypropylene Venting C. Polypropylene Venting Warning asphyxiation Hazard. Follow these instructions and the installation instructions included by the listed polypropylene venting component manufacturers, whichever applicable. Failure to do so could cause products of combustion to enter the building, resulting in severe property damage, personal injury or death.
Page 36 iV. Venting C. Polypropylene Venting (continued) Venting of Other Appliances (or Fireplace) into Chase or Adjacent Flues Prohibited! Figure 16a: Flexible PP Vent in UnUSED Masonry Chimney with Separate Combustion air intake 103448-07- 1/16...
Page 37 iV. Venting C. Polypropylene Venting (continued) Figure 16B: Flexible PP Vent in UnUSED B-vent with Separate Combustion air intake Figure 16C: Flexible M&g/DuraVent PP Vent in UnUSED B-vent with integrated Combustion air intake 103448-07 - 1/16...
Page 38 iV. Venting C. Polypropylene Venting (continued) Figure 16D: Flexible Centrotherm PP Vent in UnUSED B-vent with integrated Combustion air intake Table 8: Listed Polypropylene Vent System Manufacturers Make Model PolyPro Single Wall Rigid Vent M&G/DuraVent PolyPro Flex Flexible Vent (ALP080B through ALP285B) InnoFlue SW Rigid Vent Centrotherm Eco Systems Flex Flexible Vent (ALP080B through ALP285B)
Page 39 103448-07 - 1/16...
Page 40 103448-07- 1/16...
Page 41 Field Installation Procedure to Accept venting and/or air intake. Polypropylene Vent Piping - Wall Mounted Boiler Builds Alpine wall mounted boiler builds have a factory installed vent connector 90° elbow inside air box and air box top located combustion air collar. 103448-07 - 1/16...
Page 42 iV. Venting C. Polypropylene Venting (continued) 4. System Assembly nOTiCE Pressure drop for flexible polypropylene liner Warning is 20% greater than from rigid pipe. Multiply asphyxiation Hazard. Vent systems made by measured flexible polypropylene liner length by listed PP vent system manufacturers rely on 1.2 to obtain equivalent length.
Page 43: D. Stainless Steel Venting
iV. Venting D. Stainless Steel Venting gasket and fitting installation, optional tooling b. Refer to Figures 16C and 16D for details of availability/usage, routing through masonry B-Vent chase M&G/DuraVent or Centrotherm combination of combustion product venting and flexible vent with integrated air intake combustion air supply).
Page 44 iV. Venting D. Stainless Steel Venting (continued) Figure 17: Field installation of Two-Pipe Vent System adapter for Stainless Steel Figure 17a : Flexible Stainless Steel Vent in UnUSED Masonry Chimney with Separate Combustion air intake 103448-07- 1/16...
Page 45 iV. Venting D. Stainless Steel Venting (continued) Table 10a: U.S. Boiler Company Vent System Components (Stainless Steel) Part numbers Equivalent Feet of Vent System Component aLP080B - 210B aLP285B Pipe 3" Vent 4" Vent SS Vent Kit 102501-01 102501-02 Horizontal Vent Terminal 8116310 8116313 (Included in Kit)
Page 46 iV. Venting D. Stainless Steel Venting (continued) 1. Components d. Tighten the worm band clamp screw to secure PVC to stainless steel adapter. a. For use on models ALP080B through ALP285B, e. Do not install PVC to stainless steel adapter U.S.
Page 47 iV. Venting D. Stainless Steel Venting (continued) 4. System Assembly Warning asphyxiation Hazard. Vent systems made by Heat Fab, M&g / DuraVent and Z-Flex rely on gaskets for proper sealing. When these vent systems are used, take the following precautions: •...
Page 48: E. Removing The Existing Boiler
When there is a conflict between flexible stainless the building’s exterior surface. steel pipe (liner) manufacturer installation • Install rodent screen (not supplied) and instructions and Alpine boiler Installation, horizontal air terminal (elbow). Operating and Service Instructions, the more • Brace exterior piping if required.
Page 49 iV. Venting E. Removing the Existing Boiler (continued) Warning Asphyxiation Hazard. Flexible stainless steel vent must be installed only in an UNUSED chimney flue. A chimney flue is considered UNUSED when it is not being used for any appliance venting. Where one of the multiple flues is being used for an appliance venting, the flexible stainless vent installation is permitted through an adjacent unused flue providing a local authority having jurisdiction approves such installation.
Page 50: F. Multiple Boiler Installation Venting
iV. Venting F. Multiple Boiler Installation Venting F. Multiple Boiler Installation Venting Warning asphyxiation Hazard. no common manifold venting (vent piping and vent terminals) is permitted. nOTiCE installing multiple individual boiler vent terminations too close together may result in combustion product water vapor condensation on building surfaces, where vent terminations are placed, and subsequent frost damage.
Page 51 iV. Venting F. Multiple Boiler Installation Venting (continued) Figure 18: Multiple Boiler Direct Vent and air intake Terminations 103448-07 - 1/16...
Page 52: V. Condensate Disposal
V. Condensate Disposal A. Condensate Trap and Drain Line 1. All condensate which forms in the boiler or vent Warning system collects in the sump under heat exchanger Asphyxiation Hazard. Failure to fill the and leaves the boiler through factory installed condensate trap with water prior to boiler start- condensate trap.
Page 53 ALP080B chip replacement must be performed. A pH test or ALP105B acid test kits are available from HVAC/plumbing ALP150B distributors and should be used to measure ALP210B condensate acidity before/after neutralizer thus ALP285B indicating a need for service and chip replacement.
Page 54: Vi. Water Piping And Trim
ALP210B Boiler Models Trim Components a. Locate and remove ¾ in. NPT x close black Alpine boilers have factory supplied Miscellaneous Part nipple, ¾ in. NPT black tee, ¾ in. MPT x ¾ in. Carton (P/N 102942-01 – ALP080B through ALP210B;...
Page 55 B. Piping System To Be Employed. a. The flow rate through system must be the same Alpine boilers are designed to operate in a closed loop as through boiler and fall within limits specified pressurized system. Minimum pressure in the boiler in Table 14.
Page 56 @ 35°F ΔT @ 35°F ΔT @ 30°F ΔT @ 30°F ΔT @ 25°F ΔT @ 25°F ΔT @ 20°F ΔT @ 20°F ΔT ALP080B 13.4 ALP105B 12.8 19.1 ALP150B 11.0 13.8 12.7 ALP210B 11.1 12.9 15.5 19.4 14.4 ALP285B 1¼ 1¼...
Page 57 Vi. Water Piping and Trim C. Standard Installation Requirements (continued) 3. Alpine boiler models ALP080B through The 10th digit of the Alpine boiler part number indicates the ALP285B are factory supplied with brand of boiler circulator included with the boiler. A “T” in...
Page 58 – Usually at least two Section VIII Electrical. circulators will be required to properly install a 7. Flow Control Valve (Strongly Alpine™ Series boiler. See Paragraph B above for information on sizing the circulators. Recommended) – The flow control valve prevents flow through the 3.
Page 59 The alpine boiler heat exchanger is made from stainless steel tubular coil having relatively narrow waterways. Once filled with water, it will be subject to the effects of corrosion. Failure to take the following precautions to minimize corrosion and heat exchanger waterways overheating could result in severe boiler damage.
Page 60 103448-07- 1/16...
Page 61 103448-07 - 1/16...
Page 62 Alpine boiler heat exchanger. Some examples gravity circulation during the cooling cycle. include but not limited to: •...
Page 63 Alpine boiler compare the specified flow range through an Alpine model, the Alliance SL™ model must be piped...
Page 64 103448-07- 1/16...
Page 65 103448-07 - 1/16...
Page 66 103448-07- 1/16...
Page 67 103448-07 - 1/16...
Page 68 103448-07- 1/16...
Page 69 103448-07 - 1/16...
Page 70: Vii. Gas Piping
Vii. gas Piping 2. Maximum gas demand . Refer to the boiler’s input as printed on its rating label. Also consider Warning existing and expected future gas utilization Explosion Hazard. Failure to properly pipe gas equipment (i.e. water heater, cooking equipment). supply to boiler may result in improper operation 3.
Page 71 Vii. gas Piping (continued) Table 17B: 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 inside Length of Pipe, Ft. Pipe Size, in.
Page 72 0.65 0.96 1.00 0.78 C. Pressure test. 0.70 0.93 1.10 0.74 See Table 20 for Alpine Min./Max. Pressure Ratings. The boiler and its gas connection 0.75 0.90 1.20 0.71 must be leak tested before placing boiler in operation. 0.80 0.87 1.30...
Page 73 Vii. gas Piping (continued) DangEr CaUTiOn Explosion Hazard. Do not use matches, candles, if gas pressure in the building is above ½ psig open flames or other ignition source to check for (3.4 kPa), an additional gas pressure regulator leaks. is required.
Page 74: Viii. Electrical
Viii. Electrical DangEr Electrical Shock Hazard. Positively assure all electrical connections are unpowered before attempting installation or service of electrical components or connections of the boiler or building. Lock out all electrical boxes with padlock once power is turned off. Warning Electrical Shock Hazard.
Page 75: Internal Boiler Wiring
(amps) • 2 – “Heating Thermostat” ALP080B <2 • 3 – “DHW Temperature Switch” ALP105B <2 • 4 – “DHW Temperature Switch” ALP150B <2 • 5 – “Outdoor Sensor” ALP210B <3 • 6 – “Outdoor Sensor” ALP285B <5 • 7 – “Header Sensor”...
Page 76 103448-07- 1/16...
Page 77 103448-07 - 1/16...
Page 78 Viii. Electrical (continued) Figure 28: Ladder Diagram 103448-07- 1/16...
Page 79 Viii. Electrical (continued) Figure 29A: Modified Wiring For DHW Priority When Using Low Flow Circulator Piped Off System Header - Heating (with Central Heating Circulators) Plus alternately Piped indirect Water Heater 103448-07 - 1/16...
Page 80 Viii. Electrical (continued) Figure 29B: DHW Priority/Circulators (with Zone Panel) Piped Off System Header Wiring Schematic for Heating Zone Circulators 103448-07- 1/16...
Page 81 103448-07 - 1/16...
Page 82 103448-07- 1/16...
Page 83 103448-07 - 1/16...
Page 84 103448-07- 1/16...
Page 85 103448-07 - 1/16...
Page 86 Viii. Electrical (continued) G. Multiple Boiler Operating Information 1. Required Equipment and Setup a. Header Sensor (P/N 101935-01 or 103104-01) A header sensor must be installed and wired to the Master Sequencer “enabled” Sage2.2 Controller. The header sensor is installed on the common system piping and provides blended temperature information to the Sequence Master.
Page 87 Viii. Electrical (continued) 1. Required Equipment and Setup (continued) Figure 34: RJ45 Splitter Installation Detail d. Multiple Boiler Setup Step Description Comments Wire the header sensor to low voltage terminal strip terminals “Header sensor”. Install and wire the Header nOTE Sensor This step can not be skipped.
Page 88: Ix. System Start-Up
(in Btu per cubic foot) Warning from gas supplier. Explosion Hazard. asphyxiation Hazard. 2. Alpine gas valves have inlet and outlet Electrical Shock Hazard. Start-up of this boiler pressure taps with built-in shut off screw. Turn should be undertaken only by trained and skilled each screw from fully closed position three to four personnel from a qualified service agency.
Page 89 System Start-up (continued) Alpine™ Series Lighting and Operating Instructions Figure 35: Operating instructions 103448-07 - 1/16...
Page 90 Warning Purges the combustion chamber for the asphyxiation Hazard. Each alpine Series boiler is Postpurge 30 second purge time. tested at the factory and adjustments to the air Prevents system from running due to a fuel mixture are normally not necessary.
Page 91 ALP105B (High Fire) (High Fire) Less than Refer to Figure 37 for location of throttle screw. ALP150B 100 PPM Verify CO is less than 100 ppm. 9.9 - 7.9 3.5 - 7.0 ALP210B...
Page 92 iX. System Start-up (continued) 7. Verify measured input rate is within 88% to 100% of the max. input listed on the boiler rating Warning label. Asphyxiation Hazard. Install flue temperature 8. If measured input is too high, reduce maximum sensor and sensor cap into two-pipe vent modulation fan speed (either central heat or connector port upon completion of combustion domestic hot water, depending on source of call for...
Page 93 Alpine models ALP080 through ALP285 (-02, 27, 07 altitude range Boiler Model gas Valve altitude code builds.) are factory shipped as natural gas builds and can be field converted to LP gas. Alpine 0 - 7000 Ft. models ALP150, ALP210 and ALP285 (-70 altitude ALP080B 2¾...
Page 94 S. Correcting Throttle Screw Mis-Adjustment Position, LP gas (if required) Boiler Throttle Position (Number of Counter- Alpine boilers are fire tested at factory and gas valve Model clockwise Turns from Fully Closed Position throttle screws are preset. However, if boiler does not ALP080B...
Page 95 iX. System Start-up (continued) T. Controls Startup Check List The Control is factory programmed with default parameters. Before operating the boiler, these parameters must be checked and adjusted as necessary to conform to the site requirements. Follow the steps below, making selections and adjustments as necessary to ensure optimal boiler operation.
Page 96: Operation
X. Operation A. Overview 5. Built-in Safety Control 1. Sage2.2 Controller The Control includes safety controls designed to ensure safe and reliable operation. In addition to flame safety The Sage2.2 Controller (Control) contains features and controls the Control includes supply water temperature, capabilities which help improve heating system operation, differential water temperature, and stack temperature and efficiency.
Page 97: B. Supply Water Temperature Regulation
X. Operation (continued) B. Supply Water Temperature Regulation 5. Outdoor Air Reset If an outdoor temperature sensor is connected to the 1. Priority Demand boiler and Outdoor Reset is enabled, the Central Heat The Control accepts a call for heat (demand) from multiple and Auxiliary Heat setpoints will automatically adjusted places and responds according to it’s “Priority”.
Page 98: C. Boiler Protection Features
X. Operation (continued) C. Boiler Protection Features 5. Boiler Mounted Limit Devices The Control monitors individual limit devices: 1. Supply Water Temperature High Limit pressure switch, high limit device, condensate level The boiler is equipped with independent automatic switch, Thermal Link (ALP285B only), Burner Door reset and a manual reset high limit devices.
Page 99: D. Multiple Boiler Control Sequencer
X. Operation (continued) 6. Multiple Demands D. Multiple Boiler Control Sequencer The Sequence Master responds to Central Heat, Auxiliary 1. “Plug & Play” Multiple Boiler Control Sequencer Heat DHW and frost protection demands similar to the When multiple boilers are installed, the Control’s stand alone boiler.
Page 100: E. Boiler Sequence Of Operation
X. Operation (continued) E. Boiler Sequence of Operation 1. Normal Operation Table 28: Boiler Sequence of Operation Status Screen Display Description Priority: (burner Off, circulator(s) Off) Standby Boiler is not firing and there is no call for heat, priority equals standby. The boiler Status: is ready to respond to a call for heat.
Page 101: Using The Display
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. 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”...
Page 102: Status Screens
X. Operation E. Boiler Sequence Of Operation (continued) 3. 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”...
Page 103 X. Operation E. Boiler Sequence Of Operation (continued) 3. Status Screens (continued) Bargraph Screen Bargraph Screen The bargraph screen presents measured values for easy comparison. Included on this screen is firing rate and when the Zone Panel is connected the measure Heat Loss. Measured heat loss is the heat rate kbtu/hr sum of all active (call for heat) zones.
Page 104: Detail Screens
X. Operation E. Boiler Sequence Of Operation (continued) Circulator Status Screen 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. Head Demand Screen This screen provides the status of the boilers five (5) possible heat demands.
Page 105: Multiple Boiler Sequencer Screens
X. Operation E. Boiler Sequence Of Operation (continued) 5. Multiple Boiler Sequencer Screens available When the Sequence Master is enabled the following screens are The Sequencer Status screen is selected by “pressing” “Status” button from the “Home” screen when Sequence Master is enabled.
Page 106: F. Changing Adjustable Parameters
X. Operation F. Changing Adjustable Parameters 1. Entering Adjust Mode The Control is factory programmed to include basic modulating boiler functionality. These settings are password protected to discourage unauthorized or accidental changes to settings. User login is required to view or adjust these settings: - Press the “Adjust”...
Page 107: Adjusting Parameters
X. Operation F. Changing Adjustable Parameters (continued) 2. Adjusting Parameters (continued) 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. 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): System “Press”...
Page 108 X. Operation F. Changing Adjustable Parameters (continued) Warning asphyxiation Hazard. Boiler type is factory set and must match the boiler model. Only change the boiler type setting if you are installing a new or replacement Control. The boiler type setting determines minimum and maximum blower speeds.
Page 109 X. Operation F. Changing Adjustable Parameters (continued) Expected Heat rate adjustment Screens (HeatMatch Software) The Control is shipped with defaults that will provide improved operation. Adjustment is only required to optimize setup. The expected heat rate adjustment is used to better match boiler output to the home heating needs. After receiving a "call for heat"...
Page 110 X. Operation F. Changing Adjustable Parameters (continued) Modulation “Press” button to access the following parameters: Setup Factory Range / Choices Parameter and Description Setting Central Heat Maximum Expected Heat rate Minimum to This parameter defines the highest modulation rate the Control will go to during a central heat 100% Maximum call for heat.
Page 111 X. Operation F. Changing Adjustable Parameters (continued) “Press” Pump Setup button to access the following parameters: Factory Setting range / Choices Parameter and Description System Pump run pump for: Activates the system pump output according to selected function. Never, Never: Pump is disabled and not shown on status screen.
Page 112 X. Operation F. Changing Adjustable Parameters (continued) Example Pump Parameter selections (continued): Single boiler Indirect Water Heater (IWH)Piped to Primary, Optional Domestic Hot Water Priority. Parameter Selections: System Pump= “Central Heat , Optional Priority” Boiler Pump = “any demand” DHW Pump = “Primary Loop Piped IWH” DHW Priority Enable is optional Explanation: This piping arrangement permits the...
Page 113 X. Operation F. Changing Adjustable Parameters (continued) Example Pump Parameter selections (continued): Multiple boilers IWH Piped to Primary, Optional Domestic Hot Water Priority Sequencer Master Boiler 2 (Boiler 1) Wiring locations: Thermostat DHW call for heat System pump DHW pump Boiler Pump Sequencer Master Parameter Selections: Sequencer Master...
Page 114 X. Operation F. Changing Adjustable Parameters (continued) Contractor Setup “Press” button to access the following parameters: Contractor name For Service Contact: Press box to input contractor information. Bill Smith > < Bill Smith 12 Victory Lane Plainview, New York Save 516 123-4567 Press SAVE button to store revisions.
Page 115 X. Operation F. Changing Adjustable Parameters (continued) Central Heat “Press” button to access the following parameters: Factory range / Choices Parameter and Description Setting 180°F 60°F to 190°F Central Heat Setpoint (82.2°C) (16°C to 87.8°C) Target temperature for the central heat priority. Value also used by the outdoor air reset function. Central Heat Thermostat “Sleep”...
Page 116 X. Operation F. Changing Adjustable Parameters (continued) “Press” button to access the following parameters: Factory range / Choices Parameter and Description Setting auxiliary Heat Setpoint 180°F 60°F to 190°F Target temperature for the Auxiliary Heat priority. Value also used by the outdoor air reset (82.2°C) (16°C to 87.8°C) function.
Page 117 X. Operation F. Changing Adjustable Parameters (continued) Domestic “Press” button to access the following parameters: Hot Water Factory range / Choices Parameter and Description Setting Domestic Hot Water Setpoint 60°F (16°C) to The Domestic Hot Water (DHW) Setpoint parameter is used to create a minimum 170°F 190°F boiler water temperature setpoint that is used when DHW heat demand is “on”.
Page 118 X. Operation F. Changing Adjustable Parameters (continued) “Press” button to access the following parameters: Factory range / Choices Parameter and Description Setting Central Heat 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 45.
Page 119 X. Operation F. Changing Adjustable Parameters (continued) “Press” button to access the following parameters: Factory range / Choices Parameter and Description Setting auxiliary Heat 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 45.
Page 120 X. Operation F. Changing Adjustable Parameters (continued) Figure 45: Outdoor reset Curve - Typical for Central Heat and auxiliary Heat Central Heat Central Heat Heating Element Type Heating Element Type Setpoint Setpoint 180°F to 190°F 100°F to 140°F In Slab Radiant High Fan Coil (82.2°C to 87.8°C) (37.8°C to 60°C)
Page 121 X. Operation F. Changing Adjustable Parameters (continued) “Press” button to access the following parameters: Factory range / Choices Parameter and Description Setting Master Enable/Disable Enable, Disable The Sequencer Master Enable/Disable is used to “turn on” the Multiple Boiler Controller. Disable Warning! enable ONLY one Sequence Master.
Page 122 X. Operation F. Changing Adjustable Parameters (continued) Sequence “Press” button to access the following parameters: Slave Factory range / Choices Parameter and Description Setting Boiler Address Each boiler must be given a unique address. When ”Normal” slave selection order is used, None the boiler address is used by the Master Sequencer as the boiler start order.
Page 123 X. Operation F. Changing Adjustable Parameters (continued) “Press” button to access the following parameters: Factory range / Parameter and Description Setting Choices Central Heat Modulation Source This parameter enables the 4-20mA input to control firing rate and the thermostat input to control boiler on/off demand directly without using the internal setpoint.
Page 124: Xi. Service And Maintenance
Xi. Service and Maintenance important Product Safety information refractory Ceramic Fiber Product Warning: The Repair Parts list designates parts that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to temperatures above 1805°F, such as during direct flame contact, RCF changes into crystalline silica, a known carcinogen.
Page 125 Xi. Service and Maintenance (continued) Warning Asphyxiation Hazard. This boiler requires regular maintenance and service to operate safely. Follow the instructions contained in this manual. improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. read and understand the entire manual before attempting installation, start-up operation, or service.
Page 126 Xi. Service and Maintenance (continued) DangEr Explosion Hazard. Electrical Shock Hazard. Burn Hazard. This boiler uses flammable gas, high voltage electricity, moving parts, and very hot water under high pressure. assure that all gas and electric power supplies are off and that the water temperature is cool before attempting any disassembly or service.
Page 127 Xi. Service and Maintenance (continued) acid or alkali products is prohibited. Do not use any cleaning agents or solvents. If insulation disc has signs of damage, it must be replaced. CaUTiOn / aTTEnTiOn 8. Inspect the condensate trap to verify it is open Electrical Shock Hazard.
Page 128 Poison Hazard. Use only inhibited propylene a. The following heating system freeze protection glycol solutions specifically formulated for products are recommended for Alpine boilers: hydronic systems. Do not use ethylene glycol, which is toxic and can attack gaskets and seals Fernox™...
Page 129 Xi. Service and Maintenance (continued) E. Condensate Overflow Switch and Condensate 2. Condensate Trap Removal and Reinstallation: Trap Removal and Replacement: a. Disconnect power supply to boiler. For removal or replacement of the condensate overflow b. Remove 2 wire nuts and disconnect overflow switch switch and/or condensate trap follow the steps below.
Page 130 Xi. Service and Maintenance (continued) f. Using pliers, release spring clip securing condensate j. Insure that fresh silicon sealant is applied to the trap body to the heat exchanger bottom drain overflow switch threads and the switch is properly connection. oriented relative to the trap body - the arrow molded into the switch hex side end must face down for g.
Page 131: Xii. Troubleshooting
Xii. Troubleshooting Warning Electrical Shock Hazard. Turn off power to boiler before working on wiring. A. Troubleshooting problems where no error code is displayed. Condition Possible Cause Boiler not responding to call for heat, “Status” and Boiler is not seeing call for heat. Check thermostat or zone wiring for loose connection, “Priority”...
Page 132 Xii. Troubleshooting (continued) C. Help Screen Faults indication Condition Possible Cause Zone Panel 1 communication lost, typical for Panel 1 through 4: The zone panel’s communication was established and then lost. Check the following to correct the issue: Zone Panel 1 •...
Page 133 Xii. Troubleshooting (continued) E. Active Fault Screen Faults indication Condition Possible Cause The Limit String Status screen shows the faulty safety limit. A contact icon, either Limit String Status “open” or “closed”, graphically represents each safety limit. The “closed” contact icon is steady;...
Page 134: Lockout Condition
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.
Page 135 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.
Page 136: Xiii. Repair Parts
Xiii. repair Parts All Alpine™ Series Repair Parts may be obtained through your local U.S. Boiler Wholesale distributor. Should you require assistance in locating a U.S. Boiler distributor in your area, or have questions regarding the availability of U.S. Boiler products or repair parts, please contact U.S. Boiler Customer Service at (717) 481-8400 or Fax (717) 481-8408.
Page 137 Xiii. repair Parts (continued) Part number Description aLP080B aLP105B aLP150B aLP210B aLP285B Bare Heat Exchanger and related Components (1B through 1E) Replacement Heat Exchanger assembly (includes bare heat exchanger, supply and return water temperature sensors, air vent 102513-01 102513-02 102513-03...
Page 138 Xiii. repair Parts (continued) 2B-1 Part number Description aLP080B aLP105B aLP150B aLP210B aLP285B Blower 101527-01 101528-01 101529-01 101530-01 Blower Inlet Shroud Assembly [includes Gas Orifice; Gas Orifice O-Ring; (3x) M4x20 mm or (3x) M4x25 mm self-threading screws; Injector Plate; (4x) M4 x 10 mm flat head screws;...
Page 139 Xiii. repair Parts (continued) Part number Description aLP080B aLP105B aLP150B aLP210B aLP285B repair Condensate Trap and related Components Replacement Condensate Trap Kit 104704-01 Replacement Condensate Float Switch Kit 105005-01 Spring Clip, Condensate Trap - (2 per boiler) 101632-01 Rubber Grommet, Condensate Trap...
Page 140 Xiii. repair Parts (continued) Part number Description Sage2.2 (Programmed) 106191-01 106191-02 106191-03 Repair Kit Programmed Display Repair Kit 106217-02 (with Mounting Hardware) Repair Transformer Kit 106034-01 103448-07- 1/16...
Page 141 Xiii. repair Parts (continued) Part number Description aLP080B aLP105B aLP150B aLP210B aLP285B Jacket, Rear/Bottom Panel 101217-01 101217-02 101217-03 101217-04 101217-05 Replacement Left Side Panel Kit (includes labels, access panels, grommets and header 105184-01 105184-02 105184-03 105184-04 105184-05 gaskets) Replacement Right Side Panel Kit...
Page 142 Xiii. repair Parts (continued) Quantity Vent System Components Part number aLP080B & aLP150B & aLP285B aLP105B aLP210B 2” Schedule 40 PVC Coupling Vent Terminal 101870-01 3” Schedule 40 PVC Coupling Vent Terminal 106680-01 4” Schedule 40 PVC Coupling Vent Terminal 106681-01 2”...
Page 143 Xiii. repair Parts (continued) Part number Description aLP080B aLP105B aLP150B aLP210B aLP285B MiSCELLanEOUS ParTS CarTOn 102942-01 102942-02 Temperature/Pressure Gauge 100282-01 External Gas Shut Off Valve 806SOL0005 101615-01 Safety Relief Valve 30 PSI: 81660363 30 PSI: 81660319 Alternate Safety Relief Valve (Not Shown)
Page 144 Xiii. repair Parts (continued) Part number Description aLP080B aLP105B aLP150B aLP210B aLP285B Vent Elbow w/Flue Sensor Port 102878-01 Rear Air Box 102867-01 Bottom Securing Bracket 102870-01 Hanging Bracket, Boiler 102868-01 Hanging Bracket, Wall 102869-01 Air Collar Plate Assembly 102871-02 Air Collar Plate Gasket...
Page 145 Xiii. repair Parts (continued) Part number Description aLP080B aLP105B aLP150B aLP210B aLP285B Complete Wiring Harness (includes 10A, 10B, 10C & 10D) 102701-03 Main (Low Voltage) Harness 103009-03 High Voltage Harness 103010-02 Blower Power Harness 103012-01 Communication Harness 103011-01 Igniter Harness 105752-01 Wiring Harness, Thermal Link &...
Page 146: Appendix A - Figures
appendix a - Figures Figure Page Description number number Section I - Product Description, Specifications & Dimensional Data Models ALP080B through ALP210B (Floor Mounted) Figure 1A Models ALP080B through ALP210B (Wall or Floor Mounted) Figure 1B Model ALP285B (Floor Mounted) Figure 1C Section iii - Pre-installation &...
Page 147 appendix a - Figures (continued) Figure Page Description number number Section iV - Venting (continued) Figure 16C Flexible M&G/DuraVent PP Vent in UNUSED B-vent with Integrated Combustion Air Intake Figure 16D Flexible Centrotherm PP Vent in UNUSED B-vent with Integrated Combustion Air Intake Figure 17 Field Installation of Two-Pipe Vent System Adapter for Stainless Steel Figure 17A...
Page 148 appendix a - Figures (continued) Figure Page Description number number Section X - Operation Figure 38 Home Screen Details Figure 39 Screen Navigator Figure 40 Status Screen Overview Figure 41 Boiler Status Screen Detail Figure 42 Adjust Mode Screens Figure 43 Three Zone House with DHW Demand Priority (with Zone Control Connected) Figure 44 Expected Heat Rate Adjustment (with Zone Control Connected)
Page 149: Appendix B - Tables
Fitting & Valve Equivalent Length Table 15 Multiple Boiler Water Manifold Sizing Recommended Circulator Models for Alpine Boilers and Alliance SL Indirect Water Heaters Table 16 68 & 69 Installed as Part of Near-Boiler Piping Up to 75 Ft. Equivalent...
Page 150 appendix B - Tables (continued) Table Page Description number number Section Vii - gas Piping Maximum Capacity of Schedule 40 Black Pipe in CFH* (Natu- Table 17A ral Gas) For Gas Pressures of 0.5 psig or Less Maximum Capacity of Schedule 40 Black Pipe in CFH* (LP Table 17B Gas) For Gas Pressures of 0.5 psig or Less Table 18...
Page 151 103448-07 - 1/16...
Page 152 U.S. Boiler Company, Inc. P.O. Box 3020 Lancaster, PA 17604 1-888-432-8887 www.usboiler.net 103448-07- 1/16...

This manual is also suitable for:

Alp210b Alp080b Alp105b Alp285b

Alpine ALP150B Installation, Operating And Service Instructions

Quick Links

Troubleshooting

Related Manuals for Alpine ALP150B

Summary of Contents for Alpine ALP150B

This manual is also suitable for:

Table of Contents