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................17 B. CPVC/PVC Venting................22 C. Polypropylene Venting................. 29 D. Stainless Steel Venting................ 33 E. Removing the Existing Boiler............... 37 F.
Page 5: 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...
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Page 9: Unpacking Boiler
I. Product Description, Specifications and Dimensional Data (continued) Table 2: ratings alpine Series gas-Fired Boilers Input (MBH) ** Output 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: 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 Clearances to Combustible (and Non- 4. Alpine boilers can be installed Combustible) Material: either as floor standing (ALP080B through ALP285B) or as wall Models ALP080B through ALP210B and ALP285B: hung (ALP080B through ALP210B). Factory These boilers are listed for closet installation with the assembled floor standing models are identified with following minimum clearances –...
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: Venting
Do not exceed maximum vent/combustion air lengths listed in Table 5. Vent/combustion air b. The Alpine is a Direct Vent (sealed combustion) length restrictions are based on equivalent length boiler. Combustion air must be supplied directly of vent/combustion air pipe (total length of to the burner enclosure from outdoors and flue straight pipe plus equivalent length of fittings).
Page 18 Minimum Maximum Pipe Equivalent Equivalent Pipe Equivalent Equivalent Diameter Length Length Diameter Length Length ALP080B 3 in. (80 mm) ALP105B 135 ft. 3 in. 135 ft. (41.1 m) (80 mm) (41.1 m) 2.5 ft. 2.5 ft. ALP150B (760 mm) (760 mm) 4 in.
Page 19 iV. Venting A. General Guidelines (continued) Figure 4: Location of Vent Terminal relative to Windows, Doors, grades, Overhangs, Meters and Forced air inlets - Two-Pipe System Vent Terminal (Shown) Two-Pipe System air intake Terminal (not Shown) Table 6A: Vent System and Combustion Air System Components Equivalent Length vs.
Page 20 * Total Equivalent Length (A+B+C+D+E) = a. Use only listed vent/combustion air terminals. Horizontal Sidewall Venting: For models ALP080B and ALP285B, use tee terminals for both vent and combustion air as shown in Figure 5. Alternate snorkel terminations are shown in Figure 6A and Figure 6B.
Page 21 iV. Venting A. General Guidelines (continued) ii. If possible, locate vent and combustion air terminals on the same wall to prevent nuisance shutdowns. If not, boiler may be installed with roof vent terminal and sidewall combustion air terminal. iii. When installed on the same wall, locate vent terminal at same height or higher than combustion air terminal.
Page 22: Cpvc/Pvc Venting
iV. Venting A. General Guidelines - B. CPVC/PVC Venting (continued) n. If possible, install the vent and combustion air terminals on a wall away from the prevailing wind. Reliable operation of this boiler cannot be guaranteed if terminals are subjected to winds in excess of 40 mph (64 km/hr).
Page 23 Gasket Warning Asphyxiation Hazard. Models ALP080B through ALP210B (floor mounted) and ALP285B only: Apply supplied dielectric grease to gasket inside vent section of two-pipe vent connector. Failure to apply the grease could result in flue gas leaks from gasket rupture during vent pipe installation or gasket deterioration due to condensate exposure.
Page 24 Venting B. CPVC/PVC Venting (continued) Table 7B: CPVC/PVC Vent & Air Intake Components (Installer Provided) Required for Optional Horizontal (Snorkel) Termination Quantity aLP080B & aLP150B & Part aLP285B Vent Components aLP105B aLP210B number Horizontal (Snorkel) Horizontal (Snorkel) Horizontal (Snorkel)
Page 25 3. Near-Boiler Vent/Combustion Air Piping cement bottles. Refer to Figure 10 and the following Steps: 4. Field Installation of CPVC Vent Pipe - Wall Models ALP080B and ALP210B (floor Mounted Boiler Builds mounted) and ALP285B only: Refer to Figure 10B and the following Steps:...
Page 26 iV. Venting B. CPVC/PVC Venting (continued) 5. System Assembly Warning asphyxiation Hazard. CPVC/PVC vent piping and fittings rely on glued joints for proper sealing. Follow all manufacturer instructions and warnings when preparing pipe ends for joining and using the primer and the cement. a.
Page 27 iV. Venting B. CPVC/PVC Venting (continued) Table 8: Expansion Loop Lengths nominal Length of Loop Length Pipe Dia. Straight run “L” (in.) (in.) (Ft.) Figure 11: CPVC/PVC Expansion Loop and Offset • Install contractor provided optional trim plate on wall outside surface to cover wall opening (see Figure 12).
Page 28 iV. Venting B. CPVC/PVC Venting - C. Polypropylene Venting (continued) ii. Combustion Air Piping Vent Piping • Size combustion air pipe wall penetration • Install fire stops where vent passes through opening to allow easy insertion of the pipe. floors, ceilings or framed walls. The fire stop must close the opening between the •...
Page 29: Polypropylene Venting
12 in. Make Model (300 mm) from roof surface. Allow PolyPro Single Wall Rigid Vent M&G/ additional vertical distance for PolyPro Flex Flexible Vent (ALP080B through DuraVent ALP285B) expected snow accumulation. Provide brace as required. InnoFlue SW Rigid Vent Centrotherm...
Page 30 Field Installation Procedure To Accept 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. To accept polypropylene piping for venting and/ or combustion air (see Figure 15 “Field Installation...
Page 31 48 ft. (14.6 m). • Only cut vent pipe as permitted by the vent manufacturer in accordance with their a. Models ALP080B through ALP285B are listed instructions. When pipe is cut, cut end for vertical venting by installing flexible vent...
Page 32 When there is a conflict between flexible pipe blockage. polypropylene pipe (liner) manufacturer installation instructions and Alpine boiler e. When flexible polypropylene pipe (liner) is used Installation, Operating and Service Instructions, for combustion product venting, it must not be the more restrictive instructions shall govern.
Page 33: Stainless Steel Venting
Horizontal Vent Terminal 8116310 8116313 1. Components (Included in Kit) a. For use on models ALP080B through ALP285B, PVC to SS Vent U.S. Boiler Company offers sizes 3 in. and 4 in. Adapter 102219-01 102220-01 vent pipe and fittings shown in Table 11A. It...
Page 34 Steel Adapter into 90° Vent Elbow – Wall • Only cut vent pipe as permitted by the Mounted Boiler (W) Builds vent manufacturer in accordance with their Models ALP080B (W) through instructions. When pipe is cut, cut end must ALP210B(W): Carefully insert extended PVC...
Page 35 iV. Venting D. Stainless Steel Venting (continued) for combustion air pipe installation • At top of vent pipe length install another instructions. appropriate manufacturer’s 90° elbow so that the elbow leg is opposite the building’s ii. If galvanized piping is used, use at least two exterior surface.
Page 36 Venting D. Stainless Steel Venting (continued) c. When flexible stainless steel pipe (liner) is used a. Models ALP080B through ALP285B are listed for combustion product venting, it must be for vertical venting by installing flexible stainless installed at vertical or near vertical plane. This steel vent (M&G/DuraVent FlexNSeal brand)
Page 37: Removing The Existing Boiler
iV. Venting E. Removing the Existing Boiler (continued) E. Removing the Existing Boiler 7. Any improper operation of the common venting When an existing boiler is removed from a common system should be corrected so the installation venting system, the common venting system is likely conforms with the National Fuel Gas Code, ANSI to be too large for proper venting of the remaining Z223.1/NFPA 54 and/or the Natural Gas and...
Page 38: Multiple Boiler Installation Venting
iV. Venting F. Multiple Boiler Installation Venting (continued) 4. Mettre l’appareil inspecté en marche. Suivre les between any adjacent individual boiler vent instructions d’allumage. Régler le thermostat de terminations as well as extending the distance façon que l’appareil fonctionne de façon continue. from building surfaces to vent termination end are recommended to avoid frost damage to 5.
Page 39: 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 40 *Maximum Condensate Flow, and acidic condensate) and lose neutralizing Model effectiveness over time. Therefore, periodic condensate neutralizer maintenance and limestone 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...
Page 41: Water Piping And Trim
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; FPT Pressure Relief Valve, ¾ in. NPT Drain 102942-02 or 103676-01 – ALP285B), which includes Valve.
Page 42 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 43 Flow (gPM) inch, FPT inch, FPT @ 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...
Page 44 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 45 – 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 46 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.
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Page 49 Alpine boiler heat exchanger. Some examples gravity circulation during the cooling cycle. include but not limited to: •...
Page 50 Alpine boiler compare the specified flow range through an Alpine model, the Alliance SL™ model must be piped...
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Page 57: 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 58 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 59 Locate and remove either ½ in. NPT x 6 in. long black nipple and ½ in. NPT external gas shutoff valve (ALP080B through ALP210B), or ¾ in. NPT x 6 in. long black nipple and ¾ in. NPT external gas shutoff valve (ALP285B only).
Page 60 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 61: Electrical
• This boiler is part of a modular or multiple boiler system having a total input of 300,000 BTU/hr or greater. • This boiler is equipped with a tankless coil. This notice applies to Models aLP080B through aLP285B. nOTiCE This boiler is equipped with a high water temperature limit located inside the internal wiring of the boiler.
Page 62: Internal Boiler Wiring
Table 21: Boiler Current Draw label top to bottom): • 1 – “Heating Thermostat” nominal Current Model number (amps) • 2 – “Heating Thermostat” ALP080B <2 • 3 – “DHW Temperature Switch” ALP105B <2 • 4 – “DHW Temperature Switch” ALP150B <2...
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Page 66 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 103448-06 - 4/15...
Page 67 Viii. Electrical (continued) Figure 29B: DHW Priority/Circulators (with Zone Panel) Piped Off System Header Wiring Schematic for Heating Zone Circulators 103448-06 - 4/15...
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Page 73 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 74 Viii. Electrical (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. The Sequence Master can not be “enabled”unless a Header Sensor is installed.
Page 75: 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 76 System Start-up (continued) Alpine™ Series Lighting and Operating Instructions Figure 35: Operating instructions 103448-06 - 4/15...
Page 77 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 78 ) after Model % CO range CO, PPM each adjustment. If boiler is equipped with 2 gas ALP080B valves, throttle screw adjustments must be done 9.9 - 8.2 3.5 - 6.5 to both gas valves equally and simultaneously. ALP105B (High Fire)
Page 79 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 80 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 81 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 82 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 83: Operation
X. Operation A. Overview 5. Built-in Safety Control The Control includes safety controls designed to ensure 1. Sage2.2 Controller 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 84: Supply Water Temperature Regulation
X. Operation 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 85: Boiler Protection Features
In the event of an ignition failure, the 2. High Differential Temperature Limit control retries (ALP080B through ALP285B) 5 times The Control monitors the temperature difference and then goes into soft lockout for one hour.
Page 86: Multiple Boiler Control Sequencer
X. Operation 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 87: Boiler Sequence Of Operation
X. Operation 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 88: 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 89: 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 90 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 91: 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 92: 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 93: 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 94 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 95 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 96 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 97 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 98 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 99 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 100 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 101 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 102 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 103 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 104 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 boiler water 170°F 190°F temperature setpoint that is used when DHW heat demand is “on”.
Page 105 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 106 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 107 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 108 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. Warning! Disable enable ONLY one Sequence Master.
Page 109 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, the None boiler address is used by the Master Sequencer as the boiler start order.
Page 110 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 111: 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 112 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 113 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 114 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 115 2. System Freeze Protection: switch and/or condensate trap follow the steps below. For parts identification, refer to Section XIII “Repair Parts”. a. The following heating system freeze protection products are recommended for Alpine boilers: 1. Condensate Overflow Switch Removal and Replacement: Fernox™ Protector Alphi 11 (combined antifreeze and inhibitor).
Page 116 Xi. Service and Maintenance (continued) f. Reconnect the switch wire pigtails to the boiler steps from Condensate Overflow Switch Removal wiring and secure with wire nuts. and Replacement procedure above. g. Restore power supply to boiler. Fill up the trap j.
Page 117: 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 118 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 119 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 120: Lockout Condition
Gas pressure under minimum value shown on rating plate. • Gas line not completely purged of air. • Defective Electrode. Models ALP080B through ALP285B - flame failure • Loose burner ground connection. Ignition failure after 5 tries to restart. •...
Page 121 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 122: 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 123 Xiii. repair Parts (continued) Part number Description aLP080B aLP105B aLP150B aLP210B aLP285B Bare Heat Exchanger and related Components (1B through 1E) Bare Heat Exchanger 101931-01 101931-02 101931-03 101931-04 101931-05 Air Vent Valve 101586-01 Supply/Return Water Temp Sensor - (2 per boiler)
Page 124 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 125 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 126 XIII. Repair Parts (continued) Part Number Description Sage2.2 (Programmed) 106191-01 106191-02 106191-03 Repair Kit Programmed Display Repair Kit 106217-01 (with Mounting Hardware) Repair Transformer Kit 106034-01 103448-06 - 4/15...
Page 127 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 128 Xiii. repair Parts (continued) Quantity Vent System Components Part number aLP080B & aLP150B & aLP285B aLP105B aLP210B 3” Schedule 40 PVC Tee Vent/Combustion Air Terminal 102190-01 4” Schedule 40 PVC Tee Vent/Combustion Air Terminal 102190-02 3” Stainless Steel Rodent Screens 102191-01 4”...
Page 129 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 130 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 102871-01...
Page 131 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 132: Appendix A - Figures
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 & Boiler Mounting...
Page 133 appendix a - Figures (continued) Figure Page Description number number Section Vii - gas Piping Figure 26 Recommended Gas Piping Section Viii - Electrical Figure 27 Ladder Diagram Figure 28 64 & 66 Wiring Connections Diagram Modified Wiring For DHW Priority When Using Low Flow Circulator Piped Off System Header - Figure 29A Heating (with Central Heating Circulators) Plus Alternately Piped Indirect Water Heater DHW Priority/Circulators (with Zone Panel) Piped Off System Header Wiring Schematic for Heating...
Page 134: 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 55 & 56 Installed as Part of Near-Boiler Piping Up to 75 Ft. Equivalent Length - Indirect Water Heater...
Page 135 appendix B - Tables (continued) Table Page Description number number Section Viii - Electrical Table 21 Boiler Current Draw Section iX - System Start-Up Table 22 Typical Combustion Settings, Natural Gas Table 23 Typical Combustion Settings, LP Gas Table 24 Number of Clockwise Throttle Screw Turns for LP Conversions Table 25A Approximate Throttle Screw Adjustment Values from Fully Closed Position, Natural Gas...
Page 136 U.S. Boiler Company, Inc. P.O. Box 3020 Lancaster, PA 17604 1-888-432-8887 www.usboiler.net 103448-06 - 4/15...

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