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U.S. Boiler Company ALTAC-200 Installation, Operating And Service Instructions

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ALTA
Installation, Operating and Service Instructions for
Models:
• ALTAC-136
• ALTAC-200
Manual Contents
1.
Installer Read Before Proceeding . . . . . . . . . . .3
2.
3.
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .6
4.
How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
5.
Locating Boiler . . . . . . . . . . . . . . . . . . . . . . . . .10
6.
Preparing Boiler . . . . . . . . . . . . . . . . . . . . . . . .14
7.
General Venting . . . . . . . . . . . . . . . . . . . . . . . . .17
8.
Sidewall Direct Venting . . . . . . . . . . . . . . . . . . .24
9. Vertical Direct Venting . . . . . . . . . . . . . . . . . . .30
10. Heating System Piping . . . . . . . . . . . . . . . . . . .36
11. Domestic Water Piping . . . . . . . . . . . . . . . . . . .39
12. Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
13. Field Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
14. Condensate Disposal . . . . . . . . . . . . . . . . . . . .46
15. Start-up and Checkout . . . . . . . . . . . . . . . . . .47
16. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
17. Before Leaving Jobsite . . . . . . . . . . . . . . . . . .65
18. Service and Maintenance . . . . . . . . . . . . . . . . .66
19. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . .71
20. Internal Wiring Diagrams . . . . . . . . . . . . . . . . .86
21. Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Appendix
D. Code Required Text . . . . . . . . . . . . . . . . . . . . . .99
TO THE INSTALLER:
Affix these instructions adjacent to boiler.
Provide model number and serial number when
seeking information and support.
TO THE HOMEOWNER:
Retain these instructions for future reference.
Contact heating installer or technician for all issues
and support.
Version en Español disponible en el web del fabricante.
This boiler must only be installed, serviced, or repaired by a qualified installer, service agency or gas supplier.
Improper installation, adjustment, alteration, service or maintenance can cause severe personal injury, death,
or substantial property damage. For assistance or additional information, consult a qualified installer, service
agency, or the gas supplier. Read these instruction carefully before installing.
110327-04 - 1/22
• Combi Boiler/Water Heater
• Condensing
• Direct Vent
• Gas Fired
Page
www.usboiler.net
!
WARNING

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Summary of Contents for U.S. Boiler Company ALTAC-200

  • Page 1: Table Of Contents

    • Direct Vent Models: • Gas Fired • ALTAC-136 • ALTAC-200 Manual Contents Page Installer Read Before Proceeding ...3 Homeowner Read Before Proceeding ..5 Specifications .
  • Page 2 Combi Installation, Operating & Service Instructions ALTA The Massachusetts Board of Plumbers and Gas Fitters has listed the Alta Boiler. See the Massachusetts Board of Plumbers and Gas Fitters website 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.

  • Page 3: Installer Read Before Proceeding

    Combi Installation, Operating & Service Instructions ALTA Installer or Qualified Service Agency Read Before Proceeding NOTICE: Size boiler properly relative to design WARNING heat load or, if using DHW priority, the peak Asphyxiation Hazard, Burn Hazard, Electrical hot water load, whichever is larger. A grossly Shock Hazard.
  • Page 4 Combi Installation, Operating & Service Instructions ALTA SERVICE RECORD DATE SERVICE PERFORMED 110327-04 - 1/22...

  • Page 5: Homeowner Read Before Proceeding

    Combi Installation, Operating & Service Instructions ALTA User/Homeowner Read Before Proceeding DANGER WARNING Asphyxiation Hazard. Fire Hazard. • A qualified installer, service agency or gas supplier should annually inspect boiler including annually inspecting all vent gaskets and replacing any exhibiting damage or deterioration.

  • Page 6: Specifications

    Pressure sweat, in. psig (kPa) ALTAC-136 16.3 (413) 17.8 (453) 29.8 (757) 1-1/4 50 (345) ALTAC-200 20.4 (518) 17.8 (453) 29.8 (757) 1-1/4 50 (345) Table 3-3: Air Intake and Vent Lengths Min Length Max Length Approx. Derate at Model Number Intake/Vent Size in.
  • Page 7 ALTAC-136 112 (51) 95 (43) 41.4 (1050) 20.0 (508) 18.3 (465) 1.0 (3.8) 11.99 (1.11) ALTAC-200 135 (62) 116 (53) 41.4 (1050) 20.0 (508) 22.3 (567) 1.3 (4.9) 17.98 (1.67) Electrical Requirements: 120 VAC, 60 Hz, 1-ph. 1.6A for boiler and internal pump + current draw of any external pumps connected to boiler.

  • Page 8: How It Works

    Combi Installation, Operating & Service Instructions ALTA How It Works 1. Heat exchanger 12. Boiler supply temperature sensor (UL 353 Water flows through heat exchanger's stainless Listed) steel tubes. Heat is transferred to water as flue Dual element temperature sensor used to monitor products are cooled below point of condensation boiler water exiting heat exchanger.
  • Page 9 Combi Installation, Operating & Service Instructions ALTA How It Works (continued) Figure 4-1: How it works 110327-04 - 1/22...

  • Page 10: Locating Boiler

    Combi Installation, Operating & Service Instructions ALTA Locating Boiler 4. Locate boiler to avoid water damage in case there is a leak. If boiler must be located in an Code Requirements area sensitive to water damage, install drain WARNING pan underneath boiler and pipe to a suitable drain location.
  • Page 11 Combi Installation, Operating & Service Instructions ALTA Locating Boiler (continued) Ventilation Air 3. If 24" clearances described in (2) cannot be maintained, provide two openings into 1. Combustion air must be obtained directly room, one near floor and other near ceiling. from outdoors, however ventilation openings Top of upper opening to be within 12 in.
  • Page 12 Combi Installation, Operating & Service Instructions ALTA Locating Boiler (continued) 4. If boiler is installed in room with other Table 5-2: Corrosive Combustion Air appliances, provide adequate air for combustion Contaminants and Sources and/or ventilation in accordance with other Contaminants to avoid: appliance manufacturer's instructions and applicable code.
  • Page 13 Combi Installation, Operating & Service Instructions ALTA Locating Boiler (continued) Connecting New Boiler to Existing Vent 1. Seal any unused openings in the common venting System system. 2. Visually inspect the venting system for proper size WARNING and horizontal pitch and determine there is no Asphyxiation Hazard.

  • Page 14: Preparing Boiler

    Combi Installation, Operating & Service Instructions ALTA Preparing Boiler Unpack Boiler CAUTION Remove boiler and miscellaneous parts carton from Heavy Object. outer shipping carton. Boiler weighs up to 130 lb (59 kg). Two people are required to lift boiler onto wall mounting CAUTION bracket.
  • Page 15 Combi Installation, Operating & Service Instructions ALTA Preparing Boiler (continued) Install Vent Connector Preparing for Fuel Conversion If using LP gas. LP conversion requires (2) 1. Remove vent connector and screws from steps: gas valve setting adjustment and control miscellaneous parts carton. parameter change.
  • Page 16 Combi Installation, Operating & Service Instructions ALTA Preparing Boiler (continued) 3. For wood studs, drill 3/16 in. (4.8 mm) pilot holes Mount Boiler "A" and "B" and attach bracket using provided 1. Wall bracket is designed to mount on studs 5/16 in.

  • Page 17: General Venting

    Combi Installation, Operating & Service Instructions ALTA General Venting Direct Vent Sidewall Termination Options Figure 7-2: Sidewall Low Figure 7-3: Sidewall Figure 7-1: Sidewall Profile Termination - see Concentric Termination - Termination with Fittings - Section 8 for details see Section 8 for details see Section 8 for details Direct Vent Vertical Termination Options Figure 7-4: Vertical...
  • Page 18 Derate at Size in. Number Length ft. Length ft. Max Length (mm) 2 (60) 2.5 (0.76) 70 (21.3) ALTAC-136 3 (80) 2.5 (0.76) 135 (41.1) 2 (60) 2.5 (0.76) 70 (21.3) ALTAC-200 3 (80) 2.5 (0.76) 135 (41.1) 110327-04 - 1/22...
  • Page 19 Combi Installation, Operating & Service Instructions ALTA General Venting (continued) 5. Example equivalent length calculation for 2 in. NOTICE: PVC may not be used to penetrate vent: combustible or non-combustible walls unless all A. 1 ft. CPVC straight pipe =1 eq ft. of the following conditions are met.
  • Page 20 Combi Installation, Operating & Service Instructions ALTA General Venting (continued) PVC coupling may be used to join CPVC To vent 6. CPVC/PVC vent starter kits are available. Kits to PVC vent pipe. termination include 30 in. (760 mm) CPVC pipe, 90° short From air At least 30in.
  • Page 21 Combi Installation, Operating & Service Instructions ALTA General Venting (continued) Maximum Wall 2"* 6" 12" Thickness ("T") (50mm) (150mm) (305mm) Minimum air space 0"* 1" 1-3/4" around pipe ("C") (0mm) (25mm) (45mm) One end of opening may *Wall must be of non-combustible construction be closed PVC Vent Pipe 66"...
  • Page 22 Combi Installation, Operating & Service Instructions ALTA General Venting (continued) Polypropylene Venting Table 7-16: Listed Polypropylene Vent Materials (ULC-S636 Listed) WARNING Manufacturer Model Asphyxiation Hazard. Polypropylene Single Wall Rigid • Use only vent materials listed in Table 7-16 DuraVent to make vent connections. Consult vent PolyPro Flex manufacturer's instructions for required support InnoFlue Single Wall Rigid...
  • Page 23 Combi Installation, Operating & Service Instructions ALTA General Venting (continued) Table 7-17: Listed Polypropylene Vent Fittings DuraVent Length Centrotherm InnoFlue Selkirk PolyFlue PolyPro 2 in. (60 mm) 2PPS-LC IANS02 PF-LB Joint Connector 3 in. (80 mm) 3PPS-LC IANS03 PF-LB or 4PF-LB 2 in.

  • Page 24: Sidewall Direct Venting

    Combi Installation, Operating & Service Instructions ALTA Sidewall Direct Venting Determine Terminal Location C. Minimum 12 in. (305 mm) from inside corner. 6 ft (1.8 m) is generally recommended and WARNING required when window and/or air inlet is within Asphyxiation Hazard. 4 ft.
  • Page 25 Combi Installation, Operating & Service Instructions ALTA Sidewall Direct Venting (continued) 110327-04 - 1/22...
  • Page 26 Combi Installation, Operating & Service Instructions ALTA Sidewall Direct Venting (continued) Table 8-3: Polypropylene Sidewall Terminal Fittings CPVC/PVC or Polypropylene Fittings DuraVent Centrotherm Terminal Selkirk PolyFlue PolyPro InnoFlue WARNING UV resistant UV stabilized UV resistant Asphyxiation Hazard. single wall pipe end pipe + two pipe + two 2PF- All CPVC/PVC vent joints must be glued.
  • Page 27 Combi Installation, Operating & Service Instructions ALTA Sidewall Direct Venting (continued) Table 8-7: CPVC/PVC Low Profile Terminal Kits DuraVent & Selkirk: Remove gasket to Length Ipex Diversitech install screen From boiler 2 in. (60 mm) 397984 HVENT-2 Elbow vent connection 3 in.
  • Page 28 Combi Installation, Operating & Service Instructions ALTA Sidewall Direct Venting (continued) CPVC/PVC Concentric Terminal 3. Follow terminal manufacturer's instructions and Figure 8-11 for assembly. WARNING 4. If needed, terminal can be shortened. Follow Asphyxiation Hazard. terminal manufacturer's instructions and Figure All CPVC/PVC vent joints must be glued.
  • Page 29 Combi Installation, Operating & Service Instructions ALTA Sidewall Direct Venting (continued) Kit Size *'A' Manufacturer 7-3/8" (187mm) 1-3/4" (44mm) *Overall length of inner IPEX 3-1/2" (89mm) 2" pipe to be 'A' longer than overall 12-3/16" (310mm) 3/4" (19mm) DIVERSITECH length of outer pipe. 8-3/4"...

  • Page 30: Vertical Direct Venting

    Combi Installation, Operating & Service Instructions ALTA Vertical Direct Venting Determine Terminal Location WARNING WARNING Asphyxiation Hazard. Asphyxiation Hazard. All polypropylene vent systems rely on gaskets Follow these instructions when determining vent for sealing. Ensure gaskets are installed in terminal location. Failure to comply could result each female end of vent pipe or fitting.
  • Page 31 Combi Installation, Operating & Service Instructions ALTA Vertical Direct Venting (continued) Table 9-2: Polypropylene Vertical Terminal Fittings DuraVent & Selkirk: Elbow Remove gasket to DuraVent Centrotherm install screen Joint Selkirk PolyFlue PolyPro InnoFlue Connector Screen UV resistant UV stabilized UV resistant single wall pipe end pipe + pipe + 2PF-...
  • Page 32 Combi Installation, Operating & Service Instructions ALTA Vertical Direct Venting WARNING (continued) Asphyxiation Hazard. CPVC/PVC Concentric Terminal If using stainless steel screw to attach rain cap, always drill clearance hole in rain cap WARNING and pilot hole in vent pipe appropriate for Asphyxiation Hazard.
  • Page 33 Combi Installation, Operating & Service Instructions ALTA Vertical Direct Venting (continued) Abandoned B-vent Chase Polypropylene Concentric Terminal WARNING WARNING Asphyxiation Hazard. • Only abandoned (unused) B-vent may Asphyxiation Hazard. be used as a chase. Failure to comply All polypropylene vent systems rely on gaskets may cause product damage or improper for sealing.
  • Page 34 Combi Installation, Operating & Service Instructions ALTA Centrotherm Innoflue Vertical Direct Venting (continued) IFBK02 or IFBK03 (3.1m) B-Vent Kit Table 9-11: Polypropylene B-vent Chase B-Vent 24" (610mm) Components Flashing 12" (305mm) DuraVent Centrotherm Normal snow Selkirk PolyFlue line on roof PolyPro InnoFlue 2PF-10UV or...
  • Page 35 Combi Installation, Operating & Service Instructions ALTA Vertical Direct Venting Vent (continued) Note: Duravent Polypro Flex Abandoned Chimney Chase components shown. WARNING Asphyxiation Hazard. PPs Flex Only abandoned (unused) masonry chimney may be used as a chase. If chimney contains Clean, tight unused chimney multiple flues, all flues must be abandoned.

  • Page 36: Heating System Piping

    Combi Installation, Operating & Service Instructions ALTA Heating System Piping If replaced, replacement must have a setting General System Piping Precautions less than or equal to maximum allowable WARNING working pressure (MAWP) shown on ASME data plate located on left side of heat Asphyxiation Hazard.
  • Page 37 Combi Installation, Operating & Service Instructions ALTA Heating System Piping (continued) 5. Automatic air vent (required) B. This is a water tube boiler and this flow switch A. Factory installed manual air vent is included is therefore only effective way to provide on boiler heat exchanger, to vent heat such protection.
  • Page 38 Combi Installation, Operating & Service Instructions ALTA Heating System Piping (continued) 110327-04 - 1/22...

  • Page 39: Domestic Water Piping

    Combi Installation, Operating & Service Instructions ALTA Domestic Water Piping NOTICE: Elbows pointed toward back of boiler DANGER are recommended to start DHW piping. Scald Hazard. • Under certain conditions this boiler DHW components in this system and their functions are can deliver domestic hot water (DHW) at as follows: temperatures in excess of DHW set point on...
  • Page 40 Combi Installation, Operating & Service Instructions ALTA Domestic Water Piping (continued) 110327-04 - 1/22...
  • Page 41 Combi Installation, Operating & Service Instructions ALTA Domestic Water Piping (continued) 110327-04 - 1/22...

  • Page 42: Gas Piping

    Combi Installation, Operating & Service Instructions ALTA Gas Piping WARNING DANGER Explosion Hazard. Explosion Hazard. • Failure to properly pipe gas supply to boiler Do not use matches, candles, open flames or could cause improper operation or leaks of other ignition sources to check for leaks. Failure flammable gas resulting in severe personal to comply could result in severe personal injury, injury, death or substantial property damage.

  • Page 43: Field Wiring

    Combi Installation, Operating & Service Instructions ALTA Field Wiring Locating Field Connection Terminal Strips DANGER Field connection terminal strip locations are shown in Electrical Shock Hazard. Figure 13-1. To access terminal strips: • Disconnect electrical supply before installing or performing maintenance. 1.
  • Page 44 Combi Installation, Operating & Service Instructions ALTA Field Wiring (continued) Low Voltage Connections 1. All low voltage field connections to boiler are made on Low Voltage Connections terminal strip (see Figure 13-3) located on left side of bottom panel. Route all low voltage wiring through conduit knock out holes located on left side in 120V Boiler...
  • Page 45 Combi Installation, Operating & Service Instructions ALTA Field Wiring (continued) 2. External power must not be applied to any low See Table 16-11 for information on enabling voltage terminals - doing so may damage boiler recirculation sensor. control. Note following: LWCO wiring - Although not necessary to A.

  • Page 46: Condensate Disposal

    Combi Installation, Operating & Service Instructions ALTA Condensate Disposal C. If point of condensate disposal is above trap, WARNING it will be necessary to use a condensate Asphyxiation Hazard. pump to move condensate from boiler to Failure to install condensate drain in drain.

  • Page 47: Start-Up And Checkout

    Combi Installation, Operating & Service Instructions ALTA Start-Up and Checkout Heating System Cleaning and Treatment Fill Water Quality CAUTION NOTICE: Make sure system is filled with water meeting the following criteria: Component Damage. Proper flushing, cleaning, and water side • Hardness less than 7 grains/gallon. maintenance is highly recommended to protect •...
  • Page 48 Combi Installation, Operating & Service Instructions ALTA Start-Up and Checkout (continued) 4. Eliminate air in boiler by bleeding from heat Final Check Before Starting Boiler exchanger manual air vent on top left side of heat exchanger (Figure 15-1). WARNING A. Use 1/4 in. (6 mm) ID tubing connected to Asphyxiation Hazard.
  • Page 49 Combi Installation, Operating & Service Instructions ALTA Start-Up and Checkout (continued) LP Conversion C. Apply yellow LP gas conversion label, supplied with boiler literature packet, to jacket WARNING beside rating label. Asphyxiation Hazard. • Do not attempt to operate this boiler on LP 7.
  • Page 50 Combi Installation, Operating & Service Instructions ALTA Start-Up and Checkout (continued) 12. If there is a problem, display will show error code 16. Perform combustion test. (Figure 15-6). Refer to label on access door and WARNING Section 19 troubleshooting to diagnose error. Asphyxiation Hazard.
  • Page 51 Combi Installation, Operating & Service Instructions ALTA 10.00 Start-Up and Checkout (continued) FOR YOUR SAFETY READ BEFORE OPERATING/POUR VOTRE × × × × SECURITE LISEZ AVANT DE METTRE EN MARCHE WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.
  • Page 52 Combi Installation, Operating & Service Instructions ALTA Start-Up and Checkout (continued) Boiler Sequence of Operation Table 15-10: Boiler Sequence of Operation Status Screen Display Description Burner - Off Pump(s) - Off Three Way Valve - DHW Priority: Standby There is no call for heat, boiler is not firing and priority is "standby". Boiler is ready to Status: respond to a call for heat.

  • Page 53: Operation

    Combi Installation, Operating & Service Instructions ALTA Operation User Display Overview reset – Figure 16-1: Display Icons Table 16-2: Display descriptions When not flashing or alternating display temperature is: 120°F • DHW outlet temperature during DHW priority. • Boiler supply temperature at all other times. Visible when Central Heat demand is present.
  • Page 54 Combi Installation, Operating & Service Instructions ALTA Operation (continued) Operating Mode The STA (status) display code contains below listed Basic boiler status is displayed and DHW setpoint values. may be adjusted. Table 16-5 Managing of Status Numbers Description (see Section 19 reset Display Troubleshooting for explanation)
  • Page 55 Combi Installation, Operating & Service Instructions ALTA Operation (continued) Adjust Mode Menu Diagnostic information and Quick Menu parameters are available without entering a password. Press and Hold “menu” button for 3 seconds to access Adjust Mode. reset Press Press buttons buttons to view next to adjust...
  • Page 56 Combi Installation, Operating & Service Instructions ALTA Operation (continued) Accessing Password Protected Menus Password protected parameters are available by entering a password. Press and hold the "menu" for 3 seconds, reset Press "" or "" buttons until PAS is visible and press "enter". Press "enter"...
  • Page 57 Combi Installation, Operating & Service Instructions ALTA Operation (continued) Table 16-11: Menu A A , Quick Menu (items A06, A07, A08 and A09 visible only after password entered) Range/ Default Parameter and Description Choices A01 Boiler On/Off Switch On/Off Boiler switch allows an installer to prevent boiler starts while boiler powered and reviewing boiler settings.
  • Page 58 Combi Installation, Operating & Service Instructions ALTA Operation (continued) Table 16-12: Menu FR FR, Firing Rate (visible only after password entered) Range/ Default Parameter and Description Choices F01 Manual Modulation Enable Setting to "On" allows technician to fire at rate specified in F02. To return to Auto change setting to "Off".
  • Page 59 Combi Installation, Operating & Service Instructions ALTA Operation (continued) Table 16-13: Menu 5P 5P, , Setpoint Menu (visible only after password entered) Range/ Default Parameter and Description Choices 501 Temperature Units Sets display temperature in degrees Fahrenheit or Celsius. 0, 1 Fahrenheit Celsius 502 DHW Priority Time...
  • Page 60 Combi Installation, Operating & Service Instructions ALTA Operation (continued) Table 16-15: Menu PU PU, Pump Menu (visible only after password entered) Range/ Default Parameter and Description Choices P01 System Pump Output Select: Activates System Pump output according to selected function. System Pump Any Pump Runs during any call for heat.
  • Page 61 Combi Installation, Operating & Service Instructions ALTA Operation (continued) Table 16-16: Menu LL LL, Lead Lag Menu (visible only after password entered) Range/ Default Parameter and Description Choices L01 Lead Lag Master Enable [NOT FOR COMBI BOILERS] Used to "turn on" Multiple Boiler Controller On/Off Sequencer Master is Enabled.
  • Page 62 Combi Installation, Operating & Service Instructions ALTA Operation (continued) This section covers control features available via local display. For additional control features available via our App, see Extended Features Manual available on our website or in our App. 6. Sensorless Reset Control System Overview Control system monitors recent firing rate and The control manages all of the following boiler...
  • Page 63 Combi Installation, Operating & Service Instructions ALTA Operation (continued) 12. Priority Demand 2. High Differential Temperature Limit Control accepts a call for heat from multiple Control monitors temperature difference between places and responds to its "Priority". When more return and supply sensors. If this difference than one demand is present, higher priority exceeds 58°F (32°C) control begins to reduce demand is used to determine active boiler...
  • Page 64 Combi Installation, Operating & Service Instructions ALTA Operation (continued) Boiler Protection Features (continued) 11. Central Heating System Frost Protection 7. Flue High Limit Frost Protection starts boiler and system pump Control monitors flue gas temperature sensor and fires boiler when low outdoor air, low supply located at top of heat exchanger.

  • Page 65: Before Leaving Jobsite

    Combi Installation, Operating & Service Instructions ALTA Before Leaving Jobsite Before leaving jobsite Installed ASSE 1017 or 1070 tempering valve  Installed wall retaining clips (bottom)  Flushed heating system  Boiler and system filled with water  Air purged from boiler system ...

  • Page 66: Service And Maintenance

    Combi Installation, Operating & Service Instructions ALTA Service and Maintenance Important Product Safety Information: Refractory Ceramic Fiber Product WARNING Some boiler components use materials that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to elevated temperatures, RCF may change into crystalline silica, a known carcinogen.
  • Page 67 Combi Installation, Operating & Service Instructions ALTA Monthly Inspections: Service and Maintenance (continued) 1. Inspect vent piping and air intake piping to verify it is free from leakage and deterioration. Also verify vent and air intake terminals are WARNING unobstructed. Asphyxiation Hazard.
  • Page 68 Combi Installation, Operating & Service Instructions ALTA Service and Maintenance (continued) D. Verify gap between ignitor/flame sensor and burner is within range shown in Figure 18-3 and Table 18-4. Ignitor/Flame Sensor Burner Door Mounting Nuts (4X) Gap "A" Figure 18-1: Ignitor/flame sensor location 4.
  • Page 69 Combi Installation, Operating & Service Instructions ALTA Service and Maintenance (continued) E. Refer to Sections 7 thru 9 to re-assemble any vent system components that are Condensate Tube disassembled during this inspection and for from heat exchanger details on supporting, pitching and terminating vent system.
  • Page 70 Combi Installation, Operating & Service Instructions ALTA Service and Maintenance (continued) 16. Test boiler flow switch. A. Start with boiler in standby. B. Either close a shut off in boiler loop or unplug boiler pump at connecter. C. Initiate a call for heat and confirm that boiler shows an Active Fault (H05) indicating flow switch is open.

  • Page 71: Troubleshooting

    Combi Installation, Operating & Service Instructions ALTA Troubleshooting WARNING Electrical Shock Hazard. Turn off power to boiler before working on wiring. A. Troubleshooting with No Active Fault Code Displayed Table 19-1: Troubleshooting with No Active Fault Code Indication Possible Causes Corrective Action Display Completely Check breaker and wiring between breaker panel and...
  • Page 72 Combi Installation, Operating & Service Instructions ALTA Troubleshooting (continued) Table 19-1: Troubleshooting with No Active Fault Code (continued) Indication Possible Causes Corrective Action Low Water flow through plate heat Remove and inspect plate heat exchanger, flush exchanger. heat exchanger if required. Boiling, Kettling, or Cycle power to boiler to initiate an air elimination Air in system piping.
  • Page 73 Combi Installation, Operating & Service Instructions ALTA Troubleshooting (continued) B. Troubleshooting with Status Numbers In Operating Mode, use arrow keys ("" or "") to reach "StA". Display will then alternate between "StA" and number shown below. Table 19-2: Status Number Explanation Display Description Explanation...
  • Page 74 Combi Installation, Operating & Service Instructions ALTA Troubleshooting (continued) C. Troubleshooting with Diagnostic Codes In Diagnostic and Quick Menu Mode, use the arrow keys ("" or "") to reach "c" menu and press "enter" button to view diagnostic codes. Table 19-3: Diagnostic Menu Display Name Description...
  • Page 75 Combi Installation, Operating & Service Instructions ALTA Troubleshooting (continued) D. Troubleshooting with Active Fault Code. Control uses following codes to describe abnormal operation: Table 19-4: Lockout/Hold/Warning Symbol Description Code Type Boiler Status Description When a lockout occurs, boiler will shut down and event is stored in history, b, menu.
  • Page 76 Combi Installation, Operating & Service Instructions ALTA Troubleshooting (continued) Table 19-5: Active Fault Code and Corrective Actions (continued) Detailed Fault Code found on "b" and "c" menus in brackets, e.g. [1.0]. Code Name Possible Cause Corrective Action Verify the system is full of water and the air has been properly purged.
  • Page 77 Combi Installation, Operating & Service Instructions ALTA Troubleshooting (continued) Table 19-5: Active Fault Code and Corrective Actions (continued) Detailed Fault Code found on "b" and "c" menus in brackets, e.g. [1.0]. Code Name Possible Cause Corrective Action Inspect heat exchanger and clean flue side of heat Heat exchanger dirty.
  • Page 78 Combi Installation, Operating & Service Instructions ALTA Troubleshooting (continued) Table 19-5: Active Fault Code and Corrective Actions (continued) Detailed Fault Code found on "b" and "c" menus in brackets, e.g. [1.0]. Code Name Possible Cause Corrective Action • Remove jumper from air proving switch. Defective air proving •...
  • Page 79 Combi Installation, Operating & Service Instructions ALTA Troubleshooting (continued) Table 19-5: Active Fault Code and Corrective Actions (continued) Detailed Fault Code found on "b" and "c" menus in brackets, e.g. [1.0]. Code Name Possible Cause Corrective Action [18.0] Application Normal condition following a parameter download, set Factory parameters are not valid.
  • Page 80 Combi Installation, Operating & Service Instructions ALTA Troubleshooting (continued) Table 19-5: Active Fault Code and Corrective Actions (continued) Detailed Fault Code found on "b" and "c" menus in brackets, e.g. [1.0]. Code Name Possible Cause Corrective Action No gas, insufficient gas supply Verify no air in gas line.
  • Page 81 Combi Installation, Operating & Service Instructions ALTA Troubleshooting (continued) Table 19-5: Active Fault Code and Corrective Actions (continued) Detailed Fault Code found on "b" and "c" menus in brackets, e.g. [1.0]. Code Name Possible Cause Corrective Action Hardware Fault Control damaged. Check control, cycle power, replace if necessary.
  • Page 82 Combi Installation, Operating & Service Instructions ALTA Troubleshooting (continued) Table 19-6: Detailed Fault Code (found on"c" and "b" menus) Detailed Code Type Condition Code Anti-short cycle boiler start delay, while thermostat demand present, boiler has H01.0 Warning cycled off and restart is delayed. Urgent calibration cooling delay.
  • Page 83 Combi Installation, Operating & Service Instructions ALTA Troubleshooting (continued) Table 19-6: Detailed Fault Code (found on"c c " and "b b " menus, continued) Detailed Code Type Condition Code H17.0 Hold Control in program mode. H17.1 Hold Internal Safety Core error. E17.2 Lockout Parameter CRC error.
  • Page 84 Combi Installation, Operating & Service Instructions ALTA Troubleshooting (continued) Table 19-6: Detailed Fault Code (found on"c c " and "b b " menus, continued) Detailed Code Type Condition Code H24.0 Warning Flame signal loss in operation. H24.1 Hold Flame signal loss in stabilization phase. H24.2 Hold Flame signal loss in safety time.
  • Page 85 Combi Installation, Operating & Service Instructions ALTA Troubleshooting (continued) Table 19-7: Supply, DHW, Return Header and Table 19-8: Outdoor Air Temperature Sensor Flue Temperature Sensor Temperature versus Temperature versus Resistance (10 kOhm) Resistance (10 kOhm) Outdoor Temperature Ohms of Temperature Ohms of Resistance °F...

  • Page 86: Internal Wiring Diagrams

    Combi Installation, Operating & Service Instructions ALTA Internal Wiring Diagrams Direction of flow 110327-04 - 1/22...
  • Page 87 Combi Installation, Operating & Service Instructions ALTA Internal Wiring Diagrams (continued) 110327-04 - 1/22...
  • Page 88 Combi Installation, Operating & Service Instructions ALTA Internal Wiring Diagrams (continued) Earth Ground 120VAC/60Hz/1Ph (Line Voltage) Combustion Blower P1-8 P1-2 Internal Chassis P1-9 Overcurrent Ground Protection Boiler Control Pump Outlet A X1-5 S4962VS1014 System Pump 1.5A [System or Zone 1 Pump] P1-7 X1-8 Fuse T5.0A...

  • Page 89: Service Parts

    All service parts may be obtained through your local U.S. Boiler Company Wholesale distributor. Should you require assistance in locating a U.S. Boiler Company Distributor in your area, or have questions regarding the availability of U.S. Boiler Company products or service parts, please contact us at 1-888-432-8887 or Fax (717) 481- 8408 or at www.usboiler.net.
  • Page 90 Combi Installation, Operating & Service Instructions ALTA Service Parts (continued) Part Number Key No. Description 136 Combi 200 Combi 10A, 10B, 10C, 10D, 10E, 10F, 10G Water Pipe Gaskets 110577-01 11A, 11B, 11C, 11D Water Pipes (w/ gaskets) 110578-01 111563-01 DHW/Return Temp Sensor 110579-01 Supply Temp.
  • Page 91 Combi Installation, Operating & Service Instructions ALTA Service Parts (continued) UNLESS OTHERWISE NOT ALL DIMENSIONS IN INC TOLERANCES: X.X ±.1 X.XXX ±.005 X.XX ±.03 ANGLE ±1 PROPER U.S. Boiler Co LANCAS THIS DOCUMENT CONTAINS C AND ITS CONTENTS ARE THE S COMPANY, INC.
  • Page 92 Combi Installation, Operating & Service Instructions ALTA Service Parts (continued) Part Number Key No. Description 136 Combi 200 Combi 31A, 31B, 31C, 31D, 31E, 31F, Condensate Trap 110589-01 31G, 31H Front Door 110595-01 Vent connector 107160-01 Side panel 110725-01 111565-01 45, 46 Wall brackets 110882-01...
  • Page 93 Key No. Description 136 Combi 200 Combi Control Enclosure 111597-01 Boiler Control 111556-01 Contact U.S. Boiler Company; Provide boiler serial number Model Key 120 VAC Connection Board 110726-01 Low Voltage Connection Board 110594-01 Fuse, 0.5A, 5 x 20mm, 250V, Slow Blow Fuse, 1.0A, 5 x 20mm, 250V, Slow Blow...
  • Page 94 Combi Installation, Operating & Service Instructions ALTA Service Parts (continued) Part Number Key No. Description 136 Combi 200 Combi Ignition Harness 110598-01 Main Control Harness 110599-01 Power Harness Part Number Accessories Description 136 Combi 200 Combi 2" CPVC/PVC Vent Kit 107039-01 3"...

  • Page 95: Combination Refrigeration/Heating System

    Combi Installation, Operating & Service Instructions ALTA Appendix A Combination Refrigeration/Heating System 1. If boiler is used in connection with refrigeration 2. If boiler is connected to heating coils located in systems, boiler must be installed with chilled air handling units where they may be exposed to medium piped in parallel with the heating boiler refrigerated air, boiler piping must be equipped using appropriate valves to prevent chilled...

  • Page 96: Water Quality And Boiler Additives

    Combi Installation, Operating & Service Instructions ALTA Appendix B Water Quality and Boiler Additives Other non-metallic tubing is equipped with an The heat exchanger used in this boiler is made oxygen barrier to prevent migration of oxygen from stainless steel coils having relatively narrow into water.

  • Page 97: Special Requirements In Massachusetts

    Combi Installation, Operating & Service Instructions ALTA Appendix C Special Requirements For Side-Wall Vented Appliances In The Commonwealth of Massachusetts IMPORTANT The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4.00 and 5.00 for installation of side-wall vented gas appliances as follows: (a) For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) ft.
  • Page 98 Combi Installation, Operating & Service Instructions ALTA Appendix C Special Requirements For Side-Wall Vented Appliances In The Commonwealth of Massachusetts (continued) (c) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED. When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall include:1.

  • Page 99: Code Required Text

    Combi Installation, Operating & Service Instructions ALTA Appendix D Code Required Text See Section 5 Locating Boiler: Remove Existing Boiler 6. Une fois qu'il a été déterminé, selon la méthode indiquée ci-dessus, que chaque for context of following text: appareil raccordé au système d'évacuation Les instructions doivent comprendre le mode est mis à...
  • Page 100 Combi Installation, Operating & Service Instructions ALTA U.S. Boiler Company, Inc. P.O. Box 3020 Lancaster, PA 17604 1-888-432-8887 www.usboiler.net 110327-04 - 1/22...

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