U.S. Boiler Company ALPINE ALP500C Installation, Operating And Service Instructions
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U.S. Boiler Company ALPINE ALP500C Installation, Operating And Service Instructions

Condensing high efficiency direct vent gas - fired hot water boiler
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inSTaLLaTiOn, OPEraTing anD
SErViCE inSTrUCTiOnS FOr
COnDEnSing HigH EFFiCiEnCY
GAS - FIRED HOT WATER BOILER
Size range - 399 MBH through 800 MBH
alpine "C" Models:
• ALP399C
• ALP500C
• ALP600C
• ALP700C
• ALP800C
Warning:
Improper installation, adjustment, alteration, service or maintenance can cause property damage,
injury, or loss of life. For assistance or additional information, consult a qualified installer, service agency or the
gas supplier. This boiler requires a special venting system. Read these instructions carefully before installing.
106307-02 - 2/17
aLPinE™
DirECT VEnT
9700609
Price - $5.00
1

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Summary of Contents for U.S. Boiler Company ALPINE ALP500C

  • Page 1 http://waterheatertimer.org/Two-water-heaters.html#boiler http://waterheatertimer.org/What-size-indirect-heater.html inSTaLLaTiOn, OPEraTing anD SErViCE inSTrUCTiOnS FOr aLPinE™ COnDEnSing HigH EFFiCiEnCY DirECT VEnT GAS - FIRED HOT WATER BOILER Size range - 399 MBH through 800 MBH alpine “C” Models: • ALP399C • ALP500C • ALP600C • ALP700C • ALP800C 9700609 Warning: Improper installation, adjustment, alteration, service or maintenance can cause property damage,...
  • Page 2 IMPORTANT INFORMATION - READ CAREFULLY NOTE: The equipment shall be installed in accordance with those installation regulations enforced in the area where the installation is to be made. These regulations shall be carefully followed in all cases. Authorities having jurisdiction shall be consulted before installations are made.
  • 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............10 Venting...................... A. General Guidelines................15 B. CPVC/PVC Venting................22 C. Polypropylene Venting................. 27 D. Stainless Steel Venting................ 33 E. Optional Room Air for Combustion............35 F.

  • Page 5: Product Description, Specifications And Dimensional Data

    I. Product Description, Specifications and Dimensional Data Alpine Series boilers are condensing high efficiency gas- stamped per Section IV ‘Heating Boilers’ of ASME Boiler and Pressure Vessel Code, which provide a maximum heat fired direct vent hot water boilers designed for use in forced hot water space or space heating with indirect domestic hot transfer and simultaneous protection against flue gas product water heating systems, where supply water temperature...

  • Page 9: Unpacking Boiler

    I. Product Description, Specifications and Dimensional Data (continued) Table 3: ratings Alpine Series Gas-Fired Boilers input (MBH) Combustion Model gross Output net ratings Water Thermal number (MBH) (MBH) Efficiency (%) Efficiency (%) Min. Max. ALP399C 94.1 94.5 ALP500C 97.0 96.0 ALP600C 95.0 96.0...

  • Page 10: Pre-Installation And Boiler Mounting

    iii. Pre-installation and Boiler Mounting 1. Access to boiler front is provided through a door or removable front access panel. Warning 2. Access is provided to the condensate trap located underneath the heat exchanger. Explosion Hazard. asphyxiation Hazard. 3. Access is provided to thermal link located at boiler Electrical Shock Hazard.
  • Page 11 iii. Pre-installation and Boiler Mounting (continued) weight of boiler, water and all additional system components. Warning b. Boiler must be level to prevent condensate from backing up inside the boiler. Asphyxiation Hazard. Adequate combustion and c. Provide adequate space for condensate piping or ventilation air must be provided to assure proper a condensate pump if required.
  • Page 12 iii. Pre-installation and Boiler Mounting (continued) Figure 4: Clearances To Combustible and non-combustible Material b. Each Alpine boiler is factory packaged with H. Boiler Stacking 2 stacking boiler attachment brackets (P/N 1. For installations with unusually high space heating 101679-01) and the bracket mounting hardware and/or domestic hot water heating loads, where [six (6) self-drilling hex washer head plated #8 employing multiple boilers will offer the benefits of...
  • Page 13 iii. Pre-installation and Boiler Mounting H. Boiler Stacking (continued) • The remaining lower bracket hole must align Follow instructions in Section IV “Venting” with a matching bottom boiler left side panel of the manual for specifics of individual boiler top positioning dimple. vent termination.
  • Page 14 iii. Pre-installation and Boiler Mounting H. Boiler Stacking (continued) Figure 5: Boiler Stacking...

  • Page 15: 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 16 iV. Venting A. General Guidelines (continued) Table 7: Vent/Combustion air intake System Options Penetration Vent & intake Component reference Option Through Termination Figures Materials Table Section Structure Intake Horizontal Sidewall 90° Elbow w/ Screen 7, 8 11, 12 Vent Horizontal Sidewall Coupling w/ Screen Intake Horizontal Sidewall...
  • Page 17 iV. Venting A. General Guidelines (continued) Table 8: Vent and Combustion Air Pipe Sizes and Equivalent Lengths (applies to all Listed Vent/Combustion air System Options) Combustion air Length Vent Length approx. Derate at Boiler Option Max. Length Pipe Dia., in. Min., ft.
  • Page 19 iV. Venting A. General Guidelines (continued) b. Maintain minimum clearance to combustible intervalles de support doivent être spécifiés. materials. See Table 5 for details. Les instructions divent aussi indiquer les renseignements suivants: c. Enclose vent passing through occupied or unoccupied spaces above boiler with material les chaudières de catégories II et IV doivent être having a fire resistance rating at least equal to the installées de façon à...
  • Page 20 iV. Venting A. General Guidelines (continued) Figure 8: Direct Vent - Sidewall Snorkel Terminations Figure 9: Direct Vent - Sidewall Low Profile Termination ii. Vertical Roof Venting: Use coupling on vent be installed with roof vent terminal and and two 90° elbows turned downwards for sidewall combustion air terminal.
  • Page 21 iV. Venting A. General Guidelines (continued) j. Do not locate the vent terminal under decks or f. Locate bottom of vent terminal at least 3 ft. (900 similar structures. mm)above any forced air inlet located within 10 k. Top of terminal must be at least 24 in. (600 ft.

  • Page 22: Cpvc/Pvc Venting

    iV. Venting B. CPVC/PVC Venting (continued) q. For multiple boiler installations with vertical d. See Table 14 for CPVC/PVC installer provided roof terminals, maintain minimum 12 in. vent and combustion air components required for (300 mm) horizontal distance between adjacent optional vertical roof terminals shown in Figure boiler vent terminals.
  • Page 23 Schedule 40 PVC Pipe x 6 in. (150 mm) min. horizontal run Schedule 40 PVC Pipe x 9 in. (230 mm)min. horizontal run Table 13: Components Required for Optional Ipex Low Profile Sidewall Termination U.S. Boiler Company Description ipex Part number...
  • Page 24 iV. Venting B. CPVC/PVC Venting (continued) Figure 12: Field installation CPVC/PP/SS Vent Connector Figure 13: near-Boiler Vent/Combustion air Piping 5. Horizontal Sidewall Termination a. Plan venting system to avoid possible contact with plumbing or electrical wires. Start at a. Standard Two-Pipe Termination vent connector at boiler and work towards vent See Figure 7.
  • Page 25 Wall thimbles for CPVC/PVC pipe are The wall is 12 in. (300 mm) thick or available from U.S. Boiler Company: less P/N’s 102180-01 (3 in.), 102181-01 (4 An air space of at least of that shown in.), 103419-01(6 in.).
  • Page 26 iV. Venting B. CPVC/PVC Venting (continued) • Install screen and vent terminal (supplied with boiler), see Figure 16 for appropriate configuration. • Brace exterior piping if required. ii. Combustion Air Piping • After penetrating wall, install a Schedule 40 PVC 90° elbow so that elbow leg is in the up direction.

  • Page 27: Polypropylene Venting

    iV. Venting (continued) • Install screen and vent terminal (supplied with boiler). See Figure 16 for Warning appropriate configuration. • Brace exterior piping if required. asphyxiation Hazard. Follow these instructions ii. Combustion Air Piping and the installation instructions included by •...
  • Page 28 iV. Venting C. Polypropylene Venting (continued) ii. Install CPVC/PP/SS vent connector. Follow nOTiCE instructions in “2. Field Installation of CPVC/PP/SS Vent Connector” under “B. The venting system must be free to expand CPVC/PVC Venting.” and contract and supported in accordance iii.
  • Page 30 iV. Venting C. Polypropylene Venting (continued) nOTiCE Pressure drop for flexible polypropylene liner is 20% greater than from rigid pipe. Multiply measured flexible polypropylene liner length by 1.2 to obtain equivalent length. Maximum equivalent length of flexible polypropylene liner is 48 ft. (14.6 m). a.
  • Page 31 iV. Venting C. Polypropylene Venting (continued) chimney for combustion product venting or, combination of combustion product venting and combustion air supply). h. When there is a conflict between flexible polypropylene pipe (liner) manufacturer installation instructions and Alpine boiler Installation, Operating and Service Instructions, the more restrictive instructions shall govern.
  • Page 32 iV. Venting C. Polypropylene Venting (continued) Venting of Other Appliances (or Fireplace) into Chase or Adjacent Flues Prohibited! Figure 21: Flexible Vent in Masonry Chimney with Separate Combustion air intake...

  • Page 33: Stainless Steel Venting

    See Table 19, 20, or 21 for adapters for reduced Examine all components for possible vent diameter. shipping damage prior to installation. Table 19: U.S. Boiler Company (Heat Fab) all condensate that forms in the vent must be Vent System Components able to drain back to the boiler.
  • Page 34 iV. Venting D. Stainless Steel Venting (continued) Table 21: Z-Flex, Z-Vent (SVE Series iii, Z-Vent iii) Stainless Steel Vent System Components, Single Wall Sidewall * or roof Termination: Boiler Model nominal Pipe Diameter Boiler adapter Wall Thimble Straight Termination w/Screen ALP399C (reduced dia.) 3 in.

  • Page 35: Optional Room Air For Combustion

    iV. Venting (continued) 4. Horizontal Sidewall Vent Termination ii. Combustion Air Termination a. Standard Two-Pipe Termination • After penetrating wall, install a 90° elbow so that the elbow leg is in the up See Figure 7. direction. Vent Termination • Install maximum vertical run of 7 ft. •...

  • Page 36: Removing The Existing Boiler

    iV. Venting (continued) 3. Terminations a. For standard horizontal sidewall terminations, Warning see Figures 7 and 8. When using room air for Sources of combustion air contaminants, combustion, use 90° elbow or tee for sidewall including chlorines, chlorofluorocarbons vent termination. (CFC’s), petroleum distillates, detergents, volatile vapors or other chemicals must not be present in nOTiCE...

  • Page 37: Multiple Boiler Installation Venting

    iV. Venting (continued) 7. Any improper operation of the common venting 7. Tout mauvais fonctionnement du système system should be corrected so the installation d’évacuation commun devrat être corrigé de façon conforms with the National Fuel Gas Code, ANSI que l’installation soit conforme au National Fuel Z223.1/NFPA 54 and/or the Natural Gas and Gas Code, ANSI Z223.1/NFPA 54 et (ou) aux Propane Installation Code, CAN/CSA B149.1.
  • Page 38 iV. Venting G. Multiple Boiler Installation Venting (continued) f. Multiple individual boiler vertical vent pipes b. Each individual boiler must have own may be piped through a common conduit or combustion air pipe and terminal. Refer to chase so that one roof penetration may be made. Paragraphs A through F (as applicable) for individual boiler combustion air guidelines and g.

  • Page 40: 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 41 V. Condensate Disposal (continued) Figure 24: Condensate Trap and Drain Line B. Condensate Neutralizer Installation 3. Limestone chips will get coated by neutral salts (product of chemical reaction between limestone 1. Some jurisdictions may require that the condensate and acidic condensate) and lose neutralizing be neutralized before being disposed of.

  • Page 42: Water Piping And Trim

    Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components, and can lead to boiler failure. U.S. Boiler Company’ s Standard Warranty does not cover problems caused by oxygen contamination of boiler water or scale (lime) build-up caused by frequent addition of water.
  • Page 43 Vi. Water Piping and Trim (continued) Space heating only - refer to Tables 25 and Table 23: Flow Switch Paddle application 26 and Figure 28 “Near Boiler Piping - Boiler Flow Switch Heating Only” as applicable. Paddle Marking ii. Space heating plus indirect water heater(s) ALP399C –...
  • Page 45 Vi. Water Piping and Trim (continued) Figure 26: Factory Supplied Piping and Trim installation - aLP500C, aLP600C, aLP700C and aLP800C C. Standard Installation Requirements. The end of the discharge pipe must terminate in an unthreaded pipe. If the safety relief valve is not Observe the following guidelines when making the piped to a drain, it must terminate at least 6 in.
  • Page 46 12. An optional LWCO with manual reset remove air during initial fill. available from U.S. Boiler Company to meet local code requirements. 7. Manual Reset High Limit - Alpine boilers have factory provided UL353 listed boiler control and UL1434 listed manual reset high limit.
  • Page 47 Vi. Water Piping and Trim (continued) Table 27: Fitting and Valve Equivalent Length (cont’d) Table 27: Fitting and Valve Equivalent Length Threaded Fitting and Valve Equivalent Length (Ft) Copper Fitting and Sweat Valve Equivalent Length (Ft) Black Threaded Pipe or Copper Pipe or Valve Size Fitting or Valve Fitting or Valve...
  • Page 50 Vi. Water Piping and Trim (continued) D. Special Situation Piping Installation 2. Piping with a Chiller - If the boiler is used in Requirements conjunction with a chiller, pipe the boiler and chiller in parallel. Use isolation valves to prevent chilled Observe the following guidelines when making the water from entering the boiler.
  • Page 51 Vi. Water Piping and Trim (continued) Figure 31: isolation of the Boiler From Oxygenated Water with a Plate Heat Exchanger (iWH Piped Off System Header) E. Multiple Boiler Water Piping 3. For installations where indirect domestic hot water heater is combined with space heating, 1.

  • Page 54: Gas Piping

    Vii. gas Piping 1. Allowable pressure drop from point of delivery to boiler. Maximum allowable system Warning pressure is ½ psig (3.4 kPa). Actual point of delivery pressure may be less; contact gas supplier for Explosion Hazard. Failure to properly pipe gas additional information.
  • Page 55 Vii. gas Piping (continued) Table 32: Specific Gravity Correction Factors For materials or conditions other than those listed Specific Correction Specific Correction above, refer to National Fuel Gas Code, ANSI Z223.1/ gravity Factor gravity Factor NFPA 54 or Natural Gas and Propane Installation 0.60 1.00 0.90...
  • Page 56 Vii. gas Piping (continued) Warning Explosion Hazard. Failure to use proper thread compounds on all gas connectors may result in leaks of flammable gas. gas supply to boiler and system must be absolutely shut off prior to installing or servicing boiler gas piping. B.
  • Page 57 Vii. gas Piping (continued) C. Pressure test. 2. The low gas pressure switch See Table 33 for Alpine Min./Max. must be reset after Pressure Ratings. The boiler and its gas connection the boiler is piped to the gas supply and before it is fired.
  • Page 58 Vii. gas Piping (continued) E. Gas Piping for Multiple Boiler Installation CaUTiOn 1. Individual module (boiler) gas pipe sizing specific details - see Paragraph A. if gas pressure in the building is above ½ psig 2. Individual module (boiler) recommended gas (3.4 kPa), an additional gas pressure regulator is required.

  • Page 59: 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 60 Viii. Electrical (continued) Figure 37: PCB Locations for Field Wiring Figure 38: 120 VaC Field Wiring...
  • Page 61 Viii. Electrical (continued) 3. 24VAC low voltage connections are located on nOTiCE left side of right PCB and are shown in Figure 39. One 24V fuse and spare are provided. ALP399C When making low voltage connections, make and ALP500C use 1.6A slow-blow fuse. ALP600C, sure that no external power source is present ALP700C and ALP800C use 2.0A fast-acting fuse.
  • Page 62 Viii. Electrical (continued) Figure 40: Ladder Diagram...
  • Page 63 Viii. Electrical (continued) Figure 41: Wiring Connections Diagram...
  • Page 64 Viii. Electrical (continued) Figure 42: 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...
  • Page 70 Viii. Electrical (continued) F. Multiple Boiler Wiring b. Ethernet Cables Ethernet cables are used to connect the boiler 1. Install over-current protection in accordance network together. These are standard “straight with authority having jurisdiction or, in the absence through” cables that can be purchased at of such requirements, follow the National Electric electrical distributors.

  • Page 71: System Start-Up

    iX. System Start-up E. Confirm that the boiler and system have no water leaks. Warning Explosion Hazard. asphyxiation Hazard. nOTiCE Electrical Shock Hazard. Start-up of this boiler If it is required to perform a long term pressure should be undertaken only by trained and skilled test of the hydronic system, the boiler should personnel from a qualified service agency.
  • Page 72 iX. System Start-up (continued) Figure 48: Operating instructions...
  • Page 73 iX. System Start-up (continued) L. Upon initial start-up, the gas train will be filled with air Even if the gas line has been Warning completely purged of air, it may take several tries for any gas valve adjustments (throttle and/ ignition before a flame is established. If more than or offset) specified herein and subsequent 2 tries for ignition are needed, it will be necessary to combustion data (%O...
  • Page 74 iX. System Start-up (continued) Figure 49: Burner Flame e. If low fire O is too low (CO is too high), increase O (decrease CO ) by turning offset Warning screw counterclockwise in less than 1/8 turn Make sure that all adjustments at high fire are increments and checking the O (or CO made with the throttle, not offset screw (see...
  • Page 75 iX. System Start-up (continued) 2. Test the flow switch by disabling the primary loop circulator. The boiler must not start if flow is Warning not present. Explosion Hazard. asphyxiation Hazard. 3. Test any other external limits or other controls This conversion should be performed by a in accordance with the manufacturer’s instructions.
  • Page 76 iX. System Start-up (continued) U. Correcting Throttle Screw Mis-Adjustment (if required) Warning Alpine boilers are fire tested at factory and gas valve asphyxiation Hazard. The throttle adjustments throttle screws are preset. However, if boiler does not shown in Table 37 are approximate. The start when first turned on, and, the problem cannot final throttle setting must be found using a be remedied following “Help”...
  • Page 77 iX. System Start-up (continued) Warning asphyxiation Hazard. if the throttle is very far out of adjustment on the “rich” (counter-clockwise) side, the boiler burner may be running at 0% excess air or even with air deficiency. Operating the boiler in this condition may cause property damage, personal injury or loss of life.
  • Page 78 iX. System Start-up (continued) Table 41: Control Parameter Checklist Parameter Step Parameter Description Location Outdoor Sensor Source Select appropriate source: Not Installed, Wired or Wireless. Adjust >> Warm Weather Shutdown Selecting Enable will restrict boiler start during warm weather, but System Setup Enable/Disable only if an outdoor sensor is installed.

  • Page 79: Operation

    X. Operation saves customer fuel dollars (pre and post purge sends A. Overview heat up stack) and saves wear and tear on the boiler. 1. Sage2.2 Controller Lowering the boiler’s firing rate saves fuel dollars by The Sage2.2 Controller (Control) contains features increasing the amount of flue gas condensation, always and capabilities which help improve heating system the goal of condensing boiler installations.

  • Page 80: Supply Water Temperature Regulation

    X. Operation B. Supply Water Temperature Regulation (continued) 2. Setpoint Purpose The peer-peer network is truly “plug and play”. Communication is activated by simply connecting The Control starts and stops the boiler and modulates a RJ45 ethernet cable between boilers. The Control the boiler input from minimum (MBH) to maximum provides precise boiler coordination by sequencing (MBH) in order to heat water up to the active setpoint.

  • Page 81: Boiler Protection Features

    X. Operation C. Boiler Protection Features (continued) 7. Domestic Hot Water (DHW) Setpoint 3. Flue Temperature High Limit Upon a DHW call for heat the setpoint is either the The control monitors flue gas temperature sensor user entered DHW setpoint or the Thermostat’s “Sleep” located in vent outlet at rear of heat exchanger.

  • Page 82: Multiple Boiler Control Sequencer

    X. Operation D. Multiple Boiler Control Sequencer (continued) 3. Lead/Slave Sequencing & Equalized Run Time start sequence, air proving switch must prove open before blower starts and closed after blower starts. One boiler is a “Lead” boiler and the remaining networked If air proving switch is not in the required position, boilers are “Slaves”.
  • Page 83 X. Operation D. Multiple Boiler Control Sequencer (continued) 8. DHW Two boiler Start 11. Advanced Boiler Sequencing When the Indirect Water Heater (IWH) parameter is After there is a Call For Heat input, both header water set to “Primary Piped” and the DHW Two Boiler Start temperature and boiler firing rate percent are used to start parameter is set to “Enabled”...

  • Page 84: Boiler Sequence Of Operation

    X. Operation E. Boiler Sequence Of Operation (continued) E. Boiler Sequence of Operation 1. Normal Operation Table 44: 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 85: 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 86: 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 87 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 88: 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 89: 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 90: Changing Adjustable Parameters

    X. Operation (continued) 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 91 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 92 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 93 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 94 X. Operation F. Changing Adjustable Parameters (continued) Modulation “Press” button to access the following parameters: Setup Factory range / Parameter and Description Setting Choices 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 95 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: Pump is disabled and not shown on status screen. Never, Any Demand: Pump Runs during any call for heat.
  • Page 96 X. Operation F. Changing Adjustable Parameters (continued) Example Pump Parameter selections (continued): Single boiler Primary Piped Indirect Water Heater, Optional DHW 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 97 X. Operation F. Changing Adjustable Parameters (continued) Example Pump Parameter selections (continued): Multiple Boilers, Boiler Piped Indirect Water Heater Sequencer Master Boiler 2 (Boiler 1) Wiring locations: Enable/Disable DHW Demand System Pump DHW Pump Boiler Pump Sequencer Master Parameter Selections: Sequencer Master Enabled Indirect Water...
  • Page 98 X. Operation F. Changing Adjustable Parameters (continued) Example Pump Parameter selections (continued): Multiple Boilers, Primary Piped Indirect Water Heater, Optional DHW Priority Sequencer Master Boiler 2 (Boiler 1) Wiring locations: Enable/Disable DHW Demand System Pump DHW Pump Boiler Pump Sequencer Master Parameter Selections: Sequencer Master Enabled Indirect Water...
  • Page 99 X. Operation F. Changing Adjustable Parameters (continued) Contractor “Press” button to access the following parameters: Setup Contractor name For Service Contact: Bill Smith Press box to input contractor information. > < Bill Smith 12 Victory Lane Plainview, New York Save 516 123-4567 Press SAVE button to store revisions.
  • Page 100 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 50°F to 190°F Central Heat Setpoint (82.2°C) (10°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 101 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) (15.6°C to 87.8°C) function.
  • Page 102 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 The Domestic Hot Water (DHW) Setpoint parameter is used to create a minimum boiler water 170°F 50°F to 190°F temperature setpoint that is used when DHW heat demand is “on”.
  • Page 103 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 59.
  • Page 104 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 59.
  • Page 105 X. Operation F. Changing Adjustable Parameters (continued) Figure 59: 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 106 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 107 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 Local, boiler on/off demand directly without using the internal setpoint.
  • Page 108 X. Operation F. Changing Adjustable Parameters (continued) “Press” button to access the following parameters: NOTE Zone Control Description Setup shown for 2 panels, typical for up to 4. Use Up and DOWN Arrows for More Exit Screen without Saving Clear Entire Field Backspace Save Field and Exit Factory Setting...

  • Page 109: 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 110 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 111 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 112 Xi. Service and Maintenance (continued) prohibited. Do not use any cleaning agents or solvents. If insulation disc has signs of damage, it must be replaced. CaUTiOn / aTTEnTiOn Inspect the condensate trap to verify it is open and free Electrical Shock Hazard. Label all wires prior to from debris.
  • Page 113 6th Avenue, Altoona, PA 16602, Tel: (972) Above referenced products are available from 547-6002 and/or selected HVAC distributors. Douglas Products and Packaging, 1550 E. Old Contact U.S. Boiler Company for specific 210 Highway, Liberty, MO 64068, Tel:(877) details. 567-2560 (Toll Free) and/or selected HVAC iii.
  • Page 114 Xi. Service and Maintenance (continued) 2. Condensate Trap Removal and Reinstallation: 1. Condensate Overflow Switch Removal and Replacement: a. Disconnect power supply to boiler. a. Disconnect power supply to boiler. b. Remove 2 wire nuts and disconnect overflow switch wire pigtails from boiler wiring. b.
  • Page 115 Xi. Service and Maintenance (continued) F. Control Compartment Access j. Insure that fresh silicon sealant is applied to the overflow switch threads and the switch is properly 1. Non-stacked boiler installations: Remove top oriented relative to the trap body - the arrow molded front panel to access control compartment.

  • Page 116: 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 117 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 Zone Panel 1 issue: Setup •...
  • Page 118 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 “open” or “closed”, graphically represents each safety limit. The “closed” contact icon Limit String Status is steady;...
  • Page 119 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 120 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 121 Xii. Troubleshooting (continued) Hard Lockout Codes Displayed (continued) Lockout number Condition Possible Cause • Loose or defective gas valve harness. Check electrical Power detected at fuel valve output when connections. Fuel Valve Error fuel valve should be off. • Defective gas valve (check for 24 Vac at harness during trial for ignition before replacing valve).

  • Page 122: Repair Parts

    Should you require assistance in locating a U.S. Boiler Company representative or outlet in your area, or have questions regarding the availability of U.S. Boiler Company products or repair parts, please contact U.S. Boiler Company Customer Service at (717) 481-8400 or...
  • Page 123 Xiii. repair Parts (continued) Heat Exchanger Components Part number Description aLP399C aLP500C aLP600C aLP700C aLP800C Replacement Heat Exchanger Assembly (includes bare heat exchanger, supply and return water temperature 106464-01 106278-01 106465-01 106279-01 sensors, air vent valve and header gaskets) 1A Air Vent Valve 101586-01 1B Supply Water Temperature Sensor / High Limit Sensor 106014-01...
  • Page 124 Xiii. repair Parts (continued)
  • Page 125 Xiii. repair Parts (continued) Blower / gas Train Components Part number Description aLP399C aLP500C Replacement Blower Kit (includes blower, blower outlet gasket and hardware) 104999-01 104999-02 Blower Outlet Gasket 101345-01 105995-01 Blower Inlet Assembly (includes gas orifice, injector flange, inlet shroud (425C 101704-04 101704-05 only), swirl plate, blower adapter plate, and mounting hardware)
  • Page 127 Xiii. repair Parts (continued) Blower / gas Train Components Part number Description aLP600C aLP700C aLP800C Replacement Blower Kit (includes blower, blower outlet gasket 104999-03 and hardware) Blower Outlet Gasket 103263-01 Natural Gas: Natural Gas: Blower Inlet Assembly (includes gas orifice, injector flange, inlet 105001-01 105001-02 shroud (425 only), swirl plate, blower adapter plate, and mounting...
  • Page 128 Xiii. repair Parts (continued) Condensate Trap and related Components Part number Description aLP399C aLP500C aLP600C aLP700C aLP800C Replacement Condensate Trap Kit (includes trap, float switch, grommet, coupling, and 104704-01 105006-01 clamps) Replacement Condensate Float Switch Kit 105005-01 (includes float switch and clamp) Spring Hose Clamp, 15/16 in.
  • Page 129 Xiii. repair Parts (continued) Control Components Part number Description aLP399C aLP500C aLP600C aLP700C aLP800C Replacement Control Kit (programmed) 106498-01 106498-02 Replacement Display Kit (programmed, includes 106508-01 mounting hardware) Transformer 102516-01 103193-01 Replacement 120V PCB Kit (includes PCB, fuses, 106512-01 and hardware) Replacement Low Voltage PCB Kit (includes PCB, 106513-01 fuses, and hardware)
  • Page 131 Xiii. repair Parts (continued) Jacket and Trim Components Part number Description aLP399C aLP500C aLP600C aLP700C aLP800C Left Side Panel 106249-01 106249-02 106249-03 106249-04 Right Side Panel (includes rating label instructions) 106517-01 106517-02 106517-03 106517-04 Top Panel (includes gaskets) 106254-01 106254-02 106254-03 106254-04 Top Control Access Panel (includes label)
  • Page 132 CSD-1 Kit (not shown, 106056-01 includes man. reset high limit and immersion well; 107421-01 kit 106056-01 107421-01 includes gas pressure switches) Contact U.S. Boiler Company for LP boilers. Gas Pressure Switch Assembly 106356-01 Low Gas Pressure Switch 107654-01 High Gas Pressure Switch...
  • Page 133 Xiii. repair Parts (continued)
  • Page 134 Xiii. repair Parts (continued) Wiring Harnesses Part number Description aLP399C aLP500C aLP600C aLP700C aLP800C 10A 120V Harness 106003-01 10B Low Voltage Harness 106008-01 10C Fan Power Harness 103012-01 10D Ignition Harness 107211-01 10G GT02 Display Communication Harness 106005-01 10H Flow Switch Harness 106385-01 10J LWCO Jumper 105111-01...

  • Page 135: Appendix A - Instructions For High Altitude Installations Above 2000 Ft

    appendix a - instructions for High altitude installations above 2000 ft. Warning if installing aLP500C or aLP700C: Do not convert aLP500C to LP gas (propane) at altitudes above 6000 ft. also, do not install aLP700C LP gas (propane) at altitudes above 7800 ft. attempts to do so may result in unreliable operation, property damage, personal injury or loss of life due to carbon monoxide (CO air free) poisoning.
  • Page 136 appendix a - instructions for High altitude installations above 2000 ft. (continued) Start-up Instructions for Natural Gas or LP 8. If low fire CO is too low, increase CO turning offset screw clockwise in less than 1. Confirm Alpine boiler size, type and installed 1/8 turn increments and checking the CO altitude prior to startup.
  • Page 137 appendix a - instructions for High altitude installations above 2000 ft. (continued) Table S2: alpine altitude adjustments Percentage Derate altitude Model Fuel recommended CO range (approx. per 1000 ft) 8.6-9.2 ALP399C 2.3% 9.4-10.2 8.7-9.2 ALP500C 4.1% 9.8-10.1 8.6-9.2 2,001 ft ALP600C 0.0% to 4,500 ft...

  • Page 138: Appendix B - Figures

    appendix B - Figures Figure Page Description number number Section I - Product Description, Specifications & Dimensional Data Figure 1 Alpine - Model ALP399C Figure 2 Alpine - Model ALP500C Figure 3 Alpine - Models ALP600C and ALP700C Section iii - Pre-installation and Boiler Mounting Figure 4 Clearances To Combustible and Non-combustible Material Figure 5...
  • Page 139 appendix B - Figures (continued) Figure Page Description number number Section Vi - Water Piping and Trim (continued) Isolation of the Boiler From Oxygenated Water with A Plate Heat Exchanger Figure 30 (IWH Piped as Part of Boiler Piping) Isolation of the Boiler From Oxygenated Water with A Plate Heat Exchanger Figure 31 (IWH Piped Off System Header) Figure 32...
  • Page 140 appendix B - Figures (continued) Figure Page Description number number Section Xi - Service and Maintenance Figure 60 Igniter Electrode Gap Figure 61 Condensate Overflow Switch Orientation Figure 62 Control Compartment Access for Stacked Boiler Installations Section Xii - Troubleshooting Figure 63 Help Menu Section Xiii - repair Parts...

  • Page 141: Appendix C - Tables

    appendix C - Tables Table Page Description number number Section I - Product Description, Specifications & Dimensional Data Table 1 Specifications Table 2 Dimensions (See Figures 1, 2, and 3) Table 3 Ratings Section iii - Pre-installation and Boiler Mounting Table 4 Corrosive Combustion air Contaminants and Sources Table 5...
  • Page 142 appendix C - Tables (continued) Table Page Description number number Section Vii - gas Piping Maximum Capacity of Schedule 40 Black Pipe in CFH* (Natural Gas) For Gas Pressures of 1/2 Table 29 psi (3.4 kPa) or Less Maximum Capacity of Schedule 40 Black Pipe in CFH* (LP Gas) For Gas Pressures of 1/2 psig Table 30 (3.4 kPa) or Less Table 31...
  • Page 144 U.S. Boiler Company, Inc. P.O. Box 3020 Lancaster, PA 17604 1-888-432-8887 www.usboiler.net...

This manual is also suitable for:

Alpine alp399cAlpine alp600cAlpine alp700cAlpine alp800c

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