U.S. Boiler Company Alpine ALP080B Installation, Operating And Service Instructions
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U.S. Boiler Company Alpine ALP080B Installation, Operating And Service Instructions

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Installation, Operating and Service Instructions for
ALPINE
Residential
9700609
Models:
08 MBH through 285 MBH
As an ENERGY STAR
Company has determined that the ALPINE
Series meets the ENERGY STAR
energy efficiency established by the United States
Environmental Protection Agency (EPA).
TO THE INSTALLER:
Affix these instructions adjacent to boiler.
TO THE CONSUMER:
Retain these instructions for future reference.
WARNING
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.
103448-10 - 6/18
TM
Partner, U.S. Boiler
®
™
guidelines for
®
Improper installation, adjustment, alteration, service or maintenance can cause property
Condensing
High Efficiency
Direct Vent
Gas-Fired
Water Boiler
Price - $5.00

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Summary of Contents for U.S. Boiler Company Alpine ALP080B

  • Page 1 Installation, Operating and Service Instructions for ALPINE Condensing  High Efficiency  Direct Vent  Gas-Fired  Residential Water Boiler  9700609 Models: 08 MBH through 285 MBH As an ENERGY STAR Partner, U.S. Boiler ® Company has determined that the ALPINE ™...
  • 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. All wiring on boilers installed in the USA shall be made in accordance with the National Electrical Code and/or local regulations.
  • 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) ft. above grade, the following requirements shall be satisfied: 1.

  • Page 4: Table Of Contents

    Table of Contents Product Description, Specifications and Dimensional Data...... Unpacking Boiler..................III. Pre-Installation and Boiler Mounting ............Venting...................... A. General Guidelines................18 B. CPVC/PVC Venting................22 C. Polypropylene Venting................. D. Stainless Steel Venting................ E. Removing the Existing Boiler............... 48 F. Multiple Boiler Installation Venting............Condensate Disposal.................

  • Page 5: Product Description, Specifications And Dimensional Data

    I. Product Description, Specifications and Dimensional Data Alpine™ Series boilers are condensing high Construction of Heating Boilers’ of ASME Boiler and efficiency gas-fired direct vent hot water heating Pressure Vessel Code, which provide a maximum boilers designed for use in forced hot water space heat transfer and simultaneous protection against or space heating with indirect domestic hot water flue gas product corrosion.
  • Page 6 I. Product Description, Specifications and Dimensional Data (continued) 103448-10- 6/18...
  • Page 7 I. Product Description, Specifications and Dimensional Data (continued) 103448-10 - 6/18...
  • Page 8 I. Product Description, Specifications and Dimensional Data (continued) 103448-10- 6/18...

  • Page 9: Unpacking Boiler

    I. Product Description, Specifications and Dimensional Data (continued) Table 2: Ratings Alpine Series Gas-Fired Boilers Input (MBH) Heating Capacity AFUE Net AHRI Ratings Water Model Number (MBH) (MBH) Min. Max. ALP080B 95.0 ALP105B 95.0 ALP150B 95.0 ALP210B 95.0 ALP285B 95.0 Ratings shown are for installations at sea level and elevations up to 2000 ft.

  • Page 10: Pre-Installation And Boiler Mounting

    Natural Gas and Propane Installation Code, CAN/ boiler cycling and accelerated component CSA B149.1, or applicable provisions of local failure. U.S. Boiler Company DOES NOT building Codes. warrant failures caused by mis-sized boiler WARNING applications.
  • Page 11 III. Pre-Installation and Boiler Mounting G. General (continued) These boilers are listed for closet installation with Factory assembled floor standing models are the following minimum clearances – Top = 1 in. identified with suffix F in a boiler part number (25 mm), Front = 1 in.
  • Page 12 III. Pre-Installation and Boiler Mounting G. General (continued) a. The boiler front is accessible through a CAUTION Alpine boiler approximate dry door. weights: b. Access is provided to the condensate trap ALP080BW – 98 lbs; ALP105BW – 112 lbs; located on the left side of boiler. ALP150BW –...
  • Page 13 III. Pre-Installation and Boiler Mounting G. General (continued) drill 3/16 in. pilot holes. d. Make sure that the surface to which the boiler is mounted is plumb. g. An alternate way to locate/mark holes “A” and “B” is to use template P/N 102986-01 e.
  • Page 14 III. Pre-Installation and Boiler Mounting G. General (continued) m. See Section IV Venting; Paragraph B, 4 CAUTION The outer edges of the “Field Installation of CPVC Vent Pipe - Wall template represent minimum side, top and Mounted Boiler Builds” for instructions on bottom clearances to combustible material.
  • Page 15 III. Pre-Installation and Boiler Mounting G. General (continued) P/N 80860743]. Locate and remove the brackets and the hardware. The Stacking Boiler Attachments Bracket has three 7/32” diameter holes punched in a triangular pattern. See Figure 3 “Stacking Boiler Attachment Bracket Placement”. c.
  • Page 16 III. Pre-Installation and Boiler Mounting H. Boiler Stacking (continued) Terminating individual boiler condensate lines into common pipe prior to drain WARNING Asphyxiation Hazard. No disposal is permissible, providing common common manifold venting is permitted. Each pipe has sufficient flow capacity to handle boiler must have its own individual vent and combined condensate volume of stackable combustion air pipes and terminals.

  • Page 17: 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. •...

  • Page 18: General Guidelines

    IV. Venting A. General Guidelines A. General Guidelines 1. Listed Vent/Combustion Air Systems a. Install vent system in accordance with “Venting of Equipment” of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 or “Venting Systems and Air Supply for Appliances” of the Natural Gas and Propane Installation Code, CAN/CSA B149.1, or applicable provisions of local building codes.
  • Page 19 IV. Venting A. General Guidelines (continued) 3. Vent/Combustion Air Terminals Install venting system components on exterior of building only as specifically required by these instructions (refer to Figure 4). a. Use only listed vent/combustion air terminals. Horizontal Sidewall Venting: For models ALP080B thru ALP285B, use coupling for vent terminal and 90°...
  • Page 20 IV. Venting A. General Guidelines (continued) p. For multiple boiler installations with horizontal wall terminals, maintain minimum 12 in. (300 mm) horizontal distance between adjacent boiler vent terminals. Maintaining greater spacing is recommended to avoid frost damage to building surfaces where vent terminations are placed. q.
  • Page 21 IV. Venting A. General Guidelines (continued) Table 5A: Vent and Combustion Air Pipe Sizes and Equivalent Lengths (Applies to All Listed Vent/Combustion Air System Options) Combustion Air Length Vent Length Boiler Option Pipe Dia., in. Min., ft. Max., ft. Pipe Dia., in. Min., ft.

  • Page 22: Cpvc/Pvc Venting

    IV. Venting B. CPVC/PVC Venting Table 6: Vent/Combustion Air Equivalent Length Calculation Work Sheet Combustion Air Vent Equivalent Equivalent Component Subtotal Subtotal Equivalent Length Per Quantity Length Quantity Equivalent Length Length Piece Per Piece Straight Pipe 90° Elbow, Short Radius 90°...
  • Page 23 IV. Venting B. CPVC/PVC Venting (continued) Figure 6B: Direct Vent - Snorkel Vent and Air Intake Figure 5: Direct Vent - Vent and Air Intake Horizontal Sidewall Terminations Horizontal Sidewall Terminations Figure 6C: Split Rigid Vent Option Figure 6A: Direct Vent - Staggered Vent and Air Intake Horizontal Sidewall Terminations 103448-10 - 6/18...
  • Page 24 IV. Venting B. CPVC/PVC Venting (continued) PVC VENT PIPE CPVC VENT PIPE PITCH VENT PIPE 1/4" PER (FIRST 30" + ELBOW) FOOT TOWARDS BOILER PVC AIR INTAKE PIPE ALTERNATE ORIENTATION Figure 6D: Direct Vent - Horizontal Two-pipe Venting/Air Intake with IPEX Low Profile or DiversiTech HVENT Terminal PITCH INTAKE AWAY FROM BUILDING EXTERIOR...
  • Page 25 IV. Venting B. CPVC/PVC Venting (continued) Figure 6H: Cutting IPEX FGV or DiversiTech CVENT Concentric Terminal Figure 6J: Installation of IPEX FGV or DiversiTech CVENT Concentric Terminal thru Sidewall Figure 7A: Direct Vent - Vent and Air Intake Vertical Terminations with Flat Roof 103448-10 - 6/18...
  • Page 26 IV. Venting B. CPVC/PVC Venting (continued) Figure 7B: Direct Vent - Vertical Two-Pipe Venting/Air Intake with IPEX FGV or DiversiTech CVENT Concentric Terminal Figure 7C: Installation of IPEX FGV or DiversiTech CVENT Concentric Terminal thru Roof 103448-10- 6/18...
  • Page 27 IV. Venting B. CPVC/PVC Venting (continued) Extend vent/combustion air piping to maintain minimum vertical (‘X’) and minimum horizontal (‘Y’) distance of 12 in. (300 mm) [18 in. (460 mm) Canada] from roof surface. Allow additional vertical (‘X’) distance for expected snow accumulation. Figure 8: Direct Vent - Vent and Air Intake Vertical Terminations with Sloped Roof Figure 9: Field Installation of CPVC/PVC Two-Pipe Vent Connector with Factory Installed Flue Temperature Sensor and Sensor Cap - Floor Mounted Boiler Builds...
  • Page 28 IV. Venting B. CPVC/PVC Venting (continued) Table 6A: Expansion Loop Lengths Nominal Length of Loop Length Pipe Dia. Straight Run “L” (In.) (In.) (Ft.) Figure 10B: Field Installation of CPVC Vent Pipe - Wall Mounted Boiler Builds Figure 11: CPVC/PVC Expansion Loop and Offset 103448-10- 6/18...
  • Page 29 IV. Venting B. CPVC/PVC Venting (continued) 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 30 IV. Venting B. CPVC/PVC Venting (continued) Table 7C: CPVC/PVC Vent & Air Intake Components (Installer Provided for Optional Vertical (Roof) Termination (Applicable to Twin-Pipe Venting with Separate Vent & Air Intake Roof Terminations) Quantity Part ALP080B & ALP105B ALP150B & ALP210B Vent Components ALP285B Number...
  • Page 31 IV. Venting B. CPVC/PVC Venting (continued) 1. Components a. See Table 7A for CPVC/PVC vent and combustion air components included with boiler. b. See Table 7B for CPVC/PVC installer provided vent and combustion air components required for optional horizontal snorkel terminals shown in Figure 6B. c.
  • Page 32 IV. Venting B. CPVC/PVC Venting (continued) c. Insert provided 3 in. Schedule 40 x 30 in. long CPVC pipe through air box top combination vent/ combustion air collar vent opening and slide down with a slight twisting motion, until the pipe lower end is firmly inserted into female end of factory installed 90°...
  • Page 33 IV. Venting B. CPVC/PVC Venting (continued) Figure 13: Rodent Screen Installation, Horizontal Figure 12: Wall Penetration Clearances Vertical, Straight Vent Terminations for PVC Vent Pipe • Following the installation of factory supplied near boiler CPVC venting components (30” long pipe and 90°...
  • Page 34 IV. Venting B. CPVC/PVC Venting (continued) • Install maximum vertical run of 7 ft. (2.1 m) of Schedule 40 PVC vent pipe. See Figure 6A. • Install another PVC 90° elbow at top of vent pipe length so that elbow leg is opposite the building’s exterior surface.

  • Page 35: Polypropylene Venting

    IV. Venting B. CPVC/PVC Venting (continued) (300 mm) from roof surface. Allow additional vertical distance for expected snow accumulation. Provide brace as required. Install storm collar on combustion air pipe immediately above flashing. Apply Dow Corning Silastic 732 RTV Sealant or equivalent between combustion air pipe and storm collar to provide weather-tight seal.
  • Page 36 IV. Venting C. Polypropylene Venting (continued) Venting of Other Appliances (or Fireplace) into Chase or Adjacent Flues Prohibited! Figure 16A: Flexible PP Vent in UNUSED Masonry Chimney with Separate Combustion Air Intake 103448-10- 6/18...
  • Page 37 IV. Venting C. Polypropylene Venting (continued) Figure 16B: Flexible PP Vent in UNUSED B-vent with Separate Combustion Air Intake Figure 16C: Flexible M&G/DuraVent PP Vent in UNUSED B-vent with Integrated Combustion Air Intake 103448-10 - 6/18...
  • Page 38 IV. Venting C. Polypropylene Venting (continued) Figure 16D: Flexible Centrotherm PP Vent in UNUSED B-vent with Integrated Combustion Air Intake Table 8: Listed Polypropylene Vent System Manufacturers Make Model PolyPro Single Wall Rigid Vent M&G/DuraVent PolyPro Flex Flexible Vent (ALP080B through ALP285B) InnoFlue SW Rigid Vent Centrotherm Eco Systems Flex Flexible Vent (ALP080B through ALP285B)
  • Page 39 IV. Venting C. Polypropylene Venting (continued) Table 9A: Approved Polypropylene Pipe, Fittings and Terminations - M&G/DuraVent M&G / DuraVent Part Numbers/Sizes CPVC Side Wall/ Coupling Side Wall Roof Chimney Vertical Boiler Nominal Male Boiler Adapter, Pipe Joint Flex Adapter, PVC Adapter Termination Termination...
  • Page 40 IV. Venting C. Polypropylene Venting (continued) Table 9C: Approved Polypropylene Pipe, Fittings and Terminations – Z-Flex Z-Dens™ Z-Flex Z-Dens Part Numbers/Sizes CPVC Coupling Male Boiler Side Wall/ Extended Male Chimney Adapter, Adapter, Pipe Side Wall Roof Vertical Boiler Nominal Boiler Adapter, Flex Kit Flex PVC to...
  • Page 41 IV. Venting C. Polypropylene Venting (continued) 1. Components Alpine wall mounted boiler builds have a factory a. Listed polypropylene vent system installed vent connector 90° elbow inside air box manufacturers are shown in Table 8. It is and air box top located combustion air collar. the responsibility of the installing contractor Wall hung boilers having 3”...
  • Page 42 IV. Venting C. Polypropylene Venting (continued) WARNING Asphyxiation Hazard. g. Install the adapter connector PPS-PACL Flexible polypropylene vent must be installed (applicable to M& G/DuraVent vent system only in an UNUSED chimney. A chimney, either only) to secure PVC to PP coupling adapter single or multiple flue type, is considered to a coupling and a polypropylene rigid UNUSED when none of the flues is being used...

  • Page 43: Stainless Steel Venting

    IV. Venting D. Stainless Steel Venting e. When flexible polypropylene pipe (liner) 6. Running Flexible Polypropylene Vent is used for combustion product venting, it (Liner) Through Unused B-Vent Chase with must not be installed at an angle greater integrated Intake Air than 45 degrees from vertical plane.
  • Page 44 IV. Venting D. Stainless Steel Venting (continued) Figure 17: Field Installation of Two-Pipe Vent System Adapter for Stainless Steel Figure 17A : Flexible Stainless Steel Vent in UNUSED Masonry Chimney with Separate Combustion Air Intake 103448-10- 6/18...
  • Page 45 IV. Venting D. Stainless Steel Venting (continued) Table 10A: U.S. Boiler Company Vent System Components (Stainless Steel) Part Numbers Equivalent Feet of Vent System Component ALP080B - 210B ALP285B Pipe 3" Vent 4" Vent SS Vent Kit 102501-01 102501-02 Horizontal Vent Terminal...
  • Page 46 PVC to stainless steel adapter. a. For use on models ALP080B through e. Do not install PVC to stainless steel adapter ALP285B, U.S. Boiler Company offers at the lower combustion air supply port of sizes 3 in. and 4 in. vent pipe and fittings the two-pipe vent system connector when shown in Table 10A.
  • Page 47 IV. Venting D. Stainless Steel Venting (continued) 4. System Assembly WARNING Asphyxiation Hazard. Vent systems made by Heat Fab, M&G / DuraVent and Z-Flex rely on gaskets for proper sealing. When these vent systems are used, take the following precautions: •...

  • Page 48: Removing The Existing Boiler

    IV. Venting E. Removing the Existing Boiler b. Refer to Figure 17A for details of chimney • At top of vent pipe length install another appropriate manufacturer’s chase installation. 90° elbow so that the elbow leg c. When flexible stainless steel pipe (liner) is opposite the building’s exterior is used for combustion product venting, it surface.
  • Page 49 IV. Venting E. Removing the Existing Boiler (continued) WARNING Asphyxiation Hazard. Flexible stainless steel vent must be installed only in an UNUSED chimney flue. A chimney flue is considered UNUSED when it is not being used for any appliance venting. Where one of the multiple flues is being used for an appliance venting, the flexible stainless vent installation is permitted through an adjacent unused flue providing a local authority having jurisdiction approves such installation.

  • Page 50: Multiple Boiler Installation Venting

    IV. Venting F. Multiple Boiler Installation Venting F. Multiple Boiler Installation Venting WARNING Asphyxiation Hazard. No common manifold venting (vent piping and vent terminals) is permitted. NOTICE Installing multiple individual boiler vent terminations too close together may result in combustion product water vapor condensation on building surfaces, where vent terminations are placed, and subsequent frost damage.
  • Page 51 IV. Venting F. Multiple Boiler Installation Venting (continued) Figure 18: Multiple Boiler Direct Vent and Air Intake Terminations 103448-10 - 6/18...

  • Page 52: Condensate Disposal

    V. Condensate Disposal 6. Install tee for condensate overflow and vent as A. Condensate Trap and Drain Line shown in Figure 19. 1. All condensate which forms in the boiler or vent system collects in the sump under heat WARNING Asphyxiation Hazard.
  • Page 53 V. Condensate Disposal (continued) 3. Limestone chips will get coated by neutral Table 11: Maximum Condensate Flow salts (product of chemical reaction between Boiler *Maximum Condensate Flow, limestone and acidic condensate) and lose Model neutralizing effectiveness over time. Therefore, periodic condensate neutralizer maintenance ALP080B and limestone chip replacement must be ALP105B...

  • Page 54: 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 55 VI. Water Piping and Trim (continued) 2. Relief Valve Piping, ALP285B Boiler Model NOTICE Failure to maintain the flow through a. Locate and remove (1) ¾ in. NPT x close boiler within specified limits could result in black nipple, (1) ¾ in. NPT x 10 in. black erratic operation or premature boiler failure.
  • Page 56 VI. Water Piping and Trim (continued) It is the installer’s responsibility to insure a d. In replacement installations, it may be proper installation and where applicable, nearly impossible to get an accurate proper circulator speed setting for the measurement of piping amount and number boiler circulator to achieve a required flow of fittings in the system.
  • Page 57 VI. Water Piping and Trim (continued) Table 13: Recommended Circulators for 50 ft. Equivalent ft. Near Boiler Piping [Approximately 20 ft. Straight Pipe, (4) 90° Elbows, and (2) Full Port Ball Valves] Boiler Near-Boiler Near-Boiler Flow, GPM Combined Boiler Supply Recommended Boiler Return...
  • Page 58 VI. Water Piping and Trim (continued) 6. Manual Reset High Limit (Required by some 10. Drain Valve (Required) – Drain valve is packaged loose with boiler and must be Codes) – This control is required by ASME installed in the location shown in Figure 20 CSD-1 “Factory Supplied Piping and Trim Installation”...
  • Page 59 VI. Water Piping and Trim (continued) NOTICE The Alpine boiler heat exchanger is made from stainless steel tubular coil having relatively narrow waterways. Once filled with water, it will be subject to the effects of corrosion. Failure to take the following precautions to minimize corrosion and heat exchanger waterways overheating could result in severe boiler damage.
  • Page 60 VI. Water Piping and Trim (continued) 103448-10- 6/18...
  • Page 61 VI. Water Piping and Trim (continued) 103448-10 - 6/18...
  • Page 62 VI. Water Piping and Trim (continued) D. Special Situation Installation Requirements 2. Piping with a refrigeration system - If the boiler is used in conjunction with a refrigeration Observe the following guidelines when making the system, pipe the boiler and refrigeration actual installation of the boiler piping for special system in parallel.
  • Page 63 VI. Water Piping and Trim (continued) E. Multiple Boiler Installation Water Piping – (See a. When Alliance SL™ model coil flow rate, Table 15 and Figures 24A, 24B, 25A and 25B) required to achieve water heater rating, falls 1. Refer to this Section of this manual for: within the specified flow range for Alpine a.
  • Page 64 VI. Water Piping and Trim (continued) NOTICE Installing a low water cutoff in the system piping of multiple boilers is strongly recommended and may be required by Local Codes. Figure 24A: Multiple Boiler Water Piping w/Domestic Hot Water Heater (Page 1 of 2) 103448-10- 6/18...
  • Page 65 VI. Water Piping and Trim (continued) NOTICE Installing a low water cutoff in the system piping of multiple boilers is strongly recommended and may be required by Local Codes. Figure 24B: Multiple Boiler Water Piping w/Domestic Hot Water Heater (Page 2 of 2) 103448-10 - 6/18...
  • Page 66 VI. Water Piping and Trim (continued) 103448-10- 6/18...
  • Page 67 VI. Water Piping and Trim (continued) Full Port Y-Strainer* (Recommended) Isolation Valve * Swing Check From Previous From Previous Valve * Page Page Consult table for common pipe sizing Boiler Circulator * Full Port Isolation Valve * Purge Valve * Field-installed low water cutoff(s).
  • Page 68 VI. Water Piping and Trim (continued) Table 16: Recommended Circulator Models for Alpine Boilers and Alliance SL Indirect Water Heaters Installed as Part of Near-Boiler Piping Up to 75 Ft. Equivalent Length - Domestic Hot Water Circulator Alliance Alliance Near- Near- Alliance Req’d...
  • Page 69 VI. Water Piping and Trim (continued) Table 16 (continued): Recommended Circulator Models for Alpine Boilers and Alliance SL Indirect Water Heaters Installed as Part of Near-Boiler Piping Up to 75 Ft. Equivalent Length - Domestic Hot Water Circulator Alliance Alliance Combined Near- Near-...

  • Page 70: Gas Piping

    VII. Gas Piping WARNING Explosion Hazard. Failure to 2. Maximum gas demand. Refer to the boiler’s input as printed on its rating label. Also properly pipe gas supply to boiler may result in improper operation and damage to the boiler consider existing and expected future gas or structure.
  • Page 71 VII. Gas Piping (continued) Table 17B: Maximum Capacity of Schedule 40 Black Pipe in CFH* (LP Gas) For Gas Pressures of 0.5 psig or Less Inlet Pressure 11.0 Inch W.C.; 0.3 Inch W.C. Pressure Drop Nominal Inside Length of Pipe, Ft. Pipe Size, In.
  • Page 72 VII. Gas Piping (continued) ALP210B), or ¾ in. NPT x 6 in. long black Table 19: Specific Gravity Correction Factors nipple and ¾ in. NPT external gas shutoff Specific Correction Specific Correction valve (ALP285B only). Gravity Factor Gravity Factor b. Feed the appropriate nipple through factory 0.60 1.00 0.90...
  • Page 73 VII. Gas Piping (continued) 1. Protect boiler gas control valve. For all CAUTION testing over ½ psig (3.5kPa), boiler and its If gas pressure in the individual shutoff valve must be disconnected building is above ½ psig (3.4 kPa), an additional gas pressure regulator is required.

  • Page 74: Electrical

    VIII. Electrical DANGER Electrical Shock Hazard. Positively assure all electrical connections are unpowered before attempting installation or service of electrical components or connections of the boiler or building. Lock out all electrical boxes with padlock once power is turned off. WARNING Electrical Shock Hazard.
  • Page 75 VIII. Electrical (continued) AWM Style 2092, 300 Volt 60°C shielded cable. 2. The connections are: Connect one end of the shielding on this cable • TB1-1: Ground to ground. • TB1-2: L1 Line Voltage (Hot) NOTICE When making low voltage •...
  • Page 76 VIII. Electrical (continued) 103448-10- 6/18...
  • Page 77 VIII. Electrical (continued) 103448-10 - 6/18...
  • Page 78 VIII. Electrical (continued) Figure 28: Ladder Diagram 103448-10- 6/18...
  • Page 79 VIII. Electrical (continued) Figure 29A: Modified Wiring For DHW Priority When Using Low Flow Circulator Piped Off System Header - Heating (with Central Heating Circulators) Plus Alternately Piped Indirect Water Heater 103448-10 - 6/18...
  • Page 80 VIII. Electrical (continued) Figure 29B: DHW Priority/Circulators (with Zone Panel) Piped Off System Header Wiring Schematic for Heating Zone Circulators 103448-10- 6/18...
  • Page 81 VIII. Electrical (continued) 103448-10 - 6/18...
  • Page 82 VIII. Electrical (continued) 103448-10- 6/18...
  • Page 83 VIII. Electrical (continued) 103448-10 - 6/18...
  • Page 84 VIII. Electrical (continued) 103448-10- 6/18...
  • Page 85 VIII. Electrical (continued) 103448-10 - 6/18...
  • Page 86 VIII. Electrical (continued) G. Multiple Boiler Operating Information 1. Required Equipment and Setup a. Header Sensor (P/N 101935-01 or 103104- 01). A header sensor must be installed and wired to the Master Sequencer “enabled” Sage2.X Controller. The header sensor is installed on the common system piping and provides blended temperature information to the Sequence Master.
  • Page 87 VIII. Electrical (continued) 1. Required Equipment and Setup (continued) Multiple Boiler Communication Network TWO Boiler Communication Network 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...

  • Page 88: System Start-Up

    IX. System Start-up WARNING NOTICE If it is required to perform a long term Explosion Hazard. pressure test of the hydronic system, the boiler Asphyxiation Hazard. Electrical Shock Hazard. should first be isolated to avoid a pressure Start-up of this boiler should be undertaken loss due to the escape of air trapped in the only by trained and skilled personnel from boiler.
  • Page 89 IX. System Start-up (continued) Alpine™ Series Lighting and Operating Instructions Figure 35: Operating Instructions 103448-10 - 6/18...
  • Page 90 IX. System Start-up (continued) J. Check Gas Inlet Pressure Status Control Action Check the inlet pressure and adjust if necessary. Initiate Power-up Verify that the inlet pressure is between the upper This state is entered when a delay is and lower limits shown on the rating plate with all Standby Delay needed before allowing the burner control gas appliances on and off.
  • Page 91 IX. System Start-up (continued) Table 22: Typical Combustion Settings, WARNING Asphyxiation Hazard. Natural Gas Offset screw is adjusted at the factory to the Altitude Range specification. DO NOT touch the offset screw Boiler 0 - 7000 Ft. if measured low fire O (or CO ) is within limits Model...
  • Page 92 IX. System Start-up (continued) Example: low water condition. Amber “LOW WATER” LED should illuminate and burner should Using a meter with dial labeled 1 cubic foot turn off. per revolution, measured time is 72 seconds for 2 Revolutions, i.e. 36 seconds per 1 cubic b.
  • Page 93 IX. System Start-up (continued) Table 24: Number of Clockwise Throttle WARNING Explosion Hazard. Screw Turns for LP Conversion Asphyxiation Hazard. This conversion should Throttle Screw Turns at be performed by a qualified service agency Altitude Range Boiler Model Gas Valve in accordance with the manufacturer’s 0 - 7000 Ft.
  • Page 94 IX. System Start-up (continued) c. Apply the “Boiler Conversion Label” to a conspicuous surface on, or adjacent to, WARNING The throttle adjustment the outer boiler jacket. Fill in the date of the values shown in Table 25A and Table 25B are conversion and the name and address of approximate.
  • Page 95 IX. System Start-up (continued) T. Controls Startup Check List The Control is factory programmed with default parameters. Before operating the boiler, these parameters must be checked and adjusted as necessary to conform to the site requirements. Follow the steps below, making selections and adjustments as necessary to ensure optimal boiler operation.

  • Page 96: Operation

    X. Operation A. Overview A. Overview 5. Built-in Safety Control 1. Sage2.X Controller The Control includes safety controls designed to ensure safe and reliable operation. In addition to flame safety The Sage2.X Controller (Control) contains features controls the Control includes supply water temperature, and capabilities which help improve heating system differential water temperature, and stack temperature operation, and efficiency.

  • Page 97: Supply Water Temperature Regulation

    X. Operation B. Supply Water Temperature Regulation B. Supply Water Temperature Regulation 5. Outdoor Air Reset 1. Priority Demand If an outdoor temperature sensor is connected to the boiler and Outdoor Reset is enabled, the Central Heat The Control accepts a call for heat (demand) from and Auxiliary Heat setpoints will automatically adjusted multiple places and responds according to it’s “Priority”.

  • Page 98: Boiler Protection Features

    X. Operation C. Boiler Protection Features C. Boiler Protection Features 6. Stack High Limit The Control monitors the flue gas temperature sensor 1. Supply Water Temperature High Limit located in the vent connector. If the flue temperature The boiler is equipped with independent automatic exceeds 184°F (84.4°C), the control begins to reduce reset and a manual reset high limit devices.

  • Page 99: Multiple Boiler Control Sequencer

    X. Operation D. Multiple Boiler Control Sequencer (continued) 4. Improved Availability boiler is started the initial firing rate is 100%/2 or 50%, The following features help improve the heat when the third boiler is started the firing rate starts at availability: 200%/3 or 66%.

  • Page 100: Boiler Sequence Of Operation

    X. Operation E. Boiler Sequence of 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 101: Using The Display

    X. Operation E. Boiler Sequence Of Operation (continued) 2. Using The Display The Control includes a touch screen LCD display. The user monitors and adjusts boiler operation by selecting screen navigation “buttons” and symbols. The “Home Screen” and menu selections are shown below.

  • Page 102: Status Screens

    X. Operation E. Boiler Sequence Of Operation (continued) 3. Status Screens Boiler Status screens are the primary boiler monitoring screens. The user may simply “walk” though boiler operation by repeatedly selecting the right or left “arrow” symbol. These screens are accessed by selected the “Status”...
  • Page 103 X. Operation E. Boiler Sequence Of Operation (continued) 3. Status Screens (continued) Bargraph Screen Bargraph Screen The bargraph screen presents measured values for easy comparison. Included on this screen is firing rate and when the Zone Panel is connected the measure Heat Loss. Measured heat loss is the heat rate kbtu/hr sum of all active (call for heat) zones.

  • Page 104: Detail Screens

    X. Operation E. Boiler Sequence Of Operation (continued) Circulator Status Screen Pumping is a major part of any hydronic system. This screen provides the status of the boiler’s demand to connected pumps as well as the status of Frost Protection and pump Exercise functions. Head Demand Screen This screen provides the status of the boilers five (5) possible heat demands.

  • Page 105: Multiple Boiler Sequencer Screens

    X. Operation E. Boiler Sequence Of Operation (continued) 5. Multiple Boiler Sequencer Screens When the Sequence Master is enabled the following screens are available: The Sequencer Status screen is selected by “pressing” “Status” button from the “Home” screen when Sequence Master is enabled.

  • Page 106: Changing Adjustable Parameters

    X. Operation F. Changing Adjustable Parameters F. Changing Adjustable Parameters 1. Entering Adjust Mode The Control is factory programmed to include basic modulating boiler functionality. These settings are password protected to discourage unauthorized or accidental changes to settings. User login is required to view or adjust these settings: - Press the “Adjust”...

  • Page 107: Adjusting Parameters

    X. Operation F. Changing Adjustable Parameters (continued) 2. Adjusting Parameters (continued) The following pages describe the Control’s adjustable parameters. Parameters are presented in the order they appear on the Control’s Display, from top to bottom and, left to right. From the “Home” screen select the Adjust button to access the adjustment mode screens show below (if required, refer to the previous page to review how to enter Adjustment mode): System...
  • Page 108 X. Operation F. Changing Adjustable Parameters (continued) WARNING Asphyxiation Hazard. Boiler type is factory set and must match the boiler model. Only change the boiler type setting if you are installing a new or replacement Control. The boiler type setting determines minimum and maximum blower speeds.
  • Page 109 X. Operation F. Changing Adjustable Parameters (continued) Expected Heat Rate Adjustment Screens (HeatMatch Software) The Control is shipped with defaults that will provide improved operation. Adjustment is only required to optimize setup. The expected heat rate adjustment is used to better match boiler output to the home heating needs. After receiving a "call for heat"...
  • Page 110 X. Operation F. Changing Adjustable Parameters (continued) Modulation “Press” button to access the following parameters: Setup Factory Range / 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 111 X. Operation F. Changing Adjustable Parameters (continued) “Press” Pump Setup button to access the following parameters: Factory Range / Choices Parameter and Description Setting 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, Any Demand:...
  • Page 112 X. Operation F. Changing Adjustable Parameters (continued) Example Pump Parameter selections (continued): Single boiler Indirect Water Heater (IWH)Piped to Primary, Optional Domestic Hot Water Priority. Parameter Selections: System Pump= “Central Heat , Optional Priority” Boiler Pump = “any demand” DHW Pump = “Primary Loop Piped IWH” DHW Priority Enable is optional Explanation: This piping arrangement permits the...
  • Page 113 X. Operation F. Changing Adjustable Parameters (continued) Example Pump Parameter selections (continued): Multiple boilers IWH Piped to Primary, Optional Domestic Hot Water Priority Sequencer Master Boiler 2 (Boiler 1) Wiring locations: Thermostat DHW call for heat System pump DHW pump Boiler Pump Sequencer Master Parameter Selections: Sequencer Master...
  • Page 114 X. Operation F. Changing Adjustable Parameters (continued) Contractor Setup “Press” button to access the following parameters: Contractor Name For Service Contact: Press box to input contractor information. Bill Smith > < Bill Smith 12 Victory Lane Plainview, New York Save 516 123-4567 Press SAVE button to store revisions.
  • Page 115 X. Operation F. Changing Adjustable Parameters (continued) Central Heat “Press” button to access the following parameters: Factory Range / Choices Parameter and Description Setting 180°F 60°F to 190°F Central Heat Setpoint (82.2°C) (16°C to 87.8°C) Target temperature for the central heat priority. Value also used by the outdoor air reset function. Central Heat Thermostat “Sleep”...
  • Page 116 X. Operation F. Changing Adjustable Parameters (continued) “Press” button to access the following parameters: Factory Range / Choices Parameter and Description Setting Auxiliary Heat Setpoint 180°F 60°F to 190°F Target temperature for the Auxiliary Heat priority. Value also used by the outdoor air reset (82.2°C) (16°C to 87.8°C) function.
  • Page 117 X. Operation F. Changing Adjustable Parameters (continued) Domestic “Press” button to access the following parameters: Hot Water Factory Range / Choices Parameter and Description Setting Domestic Hot Water Setpoint 60°F (16°C) to The Domestic Hot Water (DHW) Setpoint parameter is used to create a minimum 170°F 190°F boiler water temperature setpoint that is used when DHW heat demand is “on”.
  • Page 118 X. Operation F. Changing Adjustable Parameters (continued) “Press” button to access the following parameters: Factory Range / Choices Parameter and Description Setting Central Heat Outdoor Reset Enable If an outdoor sensor is installed and Outdoor Reset is Enabled, the boiler will automatically adjust the heating zone set point temperature based on the outdoor reset curve in Figure 45.
  • Page 119 X. Operation F. Changing Adjustable Parameters (continued) “Press” button to access the following parameters: Factory Range / Choices Parameter and Description Setting Auxiliary Heat Outdoor Reset Enable If an outdoor sensor is installed and Outdoor Reset is Enabled, the boiler will automatically adjust the heating zone set point temperature based on the outdoor reset curve in Figure 45.
  • Page 120 X. Operation F. Changing Adjustable Parameters (continued) Figure 45: Outdoor Reset Curve - Typical for Central Heat and Auxiliary Heat Central Heat Central Heat Heating Element Type Heating Element Type Setpoint Setpoint 180°F to 190°F 100°F to 140°F In Slab Radiant High Fan Coil (82.2°C to 87.8°C) (37.8°C to 60°C)
  • Page 121 X. Operation F. Changing Adjustable Parameters (continued) “Press” button to access the following parameters: Factory Range / Choices Parameter and Description Setting Master Enable/Disable Enable, Disable The Sequencer Master Enable/Disable is used to “turn on” the Multiple Boiler Controller. Disable Warning! enable ONLY one Sequence Master.
  • Page 122 X. Operation F. Changing Adjustable Parameters (continued) Sequence “Press” button to access the following parameters: Slave Factory Range / Choices Parameter and Description Setting Boiler Address Each boiler must be given a unique address. When ”Normal” slave selection order is used, None the boiler address is used by the Master Sequencer as the boiler start order.
  • Page 123 X. Operation F. Changing Adjustable Parameters (continued) “Press” button to access the following parameters: Factory Range / Parameter and Description Setting Choices Central Heat Modulation Source This parameter enables the 4-20mA input to control firing rate and the thermostat input to control boiler on/off demand directly without using the internal setpoint.

  • Page 124: Service And Maintenance

    XI. Service and Maintenance Important Product Safety Information Refractory Ceramic Fiber Product WARNING The Service Parts list designates parts that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to temperatures above 1805°F, such as during direct flame contact, RCF changes into crystalline silica, a known carcinogen.
  • Page 125 XI. Service and Maintenance (continued) Asphyxiation Hazard. This boiler requires regular maintenance and service to operate safely. Follow the instructions contained in this manual. • Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Read and understand the entire manual before attempting installation, start- up operation, or service.
  • Page 126 XI. Service and Maintenance (continued) DANGER Explosion Hazard. Electrical Shock Hazard. Burn Hazard. This boiler uses flammable gas, high voltage electricity, moving parts, and very hot water under high pressure. Assure that all gas and electric power supplies are off and that the water temperature is cool before attempting any disassembly or service.
  • Page 127 XI. Service and Maintenance (continued) 7. Inspect the heat exchanger combustion CAUTION ATTENTION Electrical Shock chamber clean and vacuum any debris found Hazard. Label all wires prior to disconnection on the surfaces. If required, brush the coils when servicing controls. Wiring errors can of the heat exchanger using a non-abrasive, cause improper and dangerous operation.
  • Page 128 Avenue, Altoona, PA 16602, Tel: (972) Fernox™ Restorer (universal cleaner, 547-6002 and/or selected HVAC distributors. sludge remover, scale remover, flux Contact U.S. Boiler Company for specific residue/debris remover, corrosion inhibitor) details. ii. Fernox™ Protector (Alphi 11, CH#, Copal) ii. Sentinel X500 Inhibited Antifreeze ®...
  • Page 129 XI. Service and Maintenance (continued) body making sure it is properly oriented - the WARNING Poison Hazard. Use arrow molded into the switch hex end side only inhibited propylene glycol solutions must face down for proper switch operation. specifically formulated for hydronic systems. See Figure 47 “Condensate Overflow Switch Do not use ethylene glycol, which is toxic and Orientation”...
  • Page 130 XI. Service and Maintenance (continued) c. Disconnect pressure switch hose from i. If the original condensate overflow switch is condensate trap. to be re-used, follow the appropriate switch removal steps from Condensate Overflow d. Disconnect outside condensate compression Switch Removal and Replacement procedure fitting from condensate trap.

  • Page 131: Troubleshooting

    XII. Troubleshooting WARNING Electrical Shock Hazard. Turn off power to boiler before working on wiring. A. Troubleshooting problems where no error code is displayed. Condition Possible Cause Boiler not responding to call for heat, “Status” and Boiler is not seeing call for heat. Check thermostat or zone wiring for loose connection, “Priority”...
  • Page 132 XII. Troubleshooting (continued) C. Help Screen Faults Indication Condition Possible Cause Zone Panel 1 communication lost, typical for Panel 1 through 4: The zone panel’s communication was established and then lost. Check the following to correct the issue: Zone Panel 1 •...
  • Page 133 XII. Troubleshooting (continued) E. Active Fault Screen Faults Indication Condition Possible Cause The Limit String Status screen shows the faulty safety limit. A contact icon, either Limit String Status “open” or “closed”, graphically represents each safety limit. The “closed” contact icon is steady;...
  • Page 134 XII. Troubleshooting (continued) F. Troubleshooting problems where a Soft Lockout Code is displayed. When a soft lockout occurs, the boiler will shut down, the display will turn red and the “Help” button will “blink” . Select the “blinking” “Help” button to determine the cause of the soft lockout.
  • Page 135 XII. Troubleshooting (continued) G. Troubleshooting problems where a Hard Lockout Code is displayed. When a hard lockout occurs, the boiler will shut down, the display will turn red and the “Help” button will “blink”. Select the “blinking” “Help” button to determine the cause of the Hard Lockout.

  • Page 136: Repair Parts

    XIII. Repair Parts All Alpine™ Series Repair Parts may be obtained through your local U.S. Boiler Wholesale distributor. Should you require assistance in locating a U.S. Boiler distributor in your area, or have questions regarding the availability of U.S. Boiler products or repair parts, please contact U.S. Boiler Customer Service at (717) 481-8400 or Fax (717) 481-8408.
  • Page 137 XIII. Repair Parts (continued) Part Number Description ALP080B ALP105B ALP150B ALP210B ALP285B Bare Heat Exchanger and Related Components (1B through 1E) Replacement Heat Exchanger assembly (includes bare heat exchanger, supply and return water temperature sensors, air vent 102513-01 102513-02 102513-03 102513-04 102513-05 valve, high limit, header gaskets)
  • Page 138 XIII. Repair Parts (continued) 2B-1 Part Number Description ALP080B ALP105B ALP150B ALP210B ALP285B 2A, 2E Blower Repair Kit (includes blower, hardware, and gasket) 105756-01 105757-01 105758-01 104999-01 Blower Inlet Shroud Assembly [includes Gas Orifice; Gas Orifice O-Ring; (3x) M4x20 mm or (3x) M4x25 mm self-threading screws;...
  • Page 139 XIII. Repair Parts (continued) Part Number Description ALP080B ALP105B ALP150B ALP210B ALP285B Repair Condensate Trap and Related Components Replacement Condensate Trap Kit 104704-01 Replacement Condensate Float Switch Kit 105005-01 Spring Clip, Condensate Trap - (2 per boiler) 101632-01 Rubber Grommet, Condensate Trap 101595-01 Air Pressure Switch 104425-01...
  • Page 140 XIII. Repair Parts (continued) Part Number Description Sage2.X (Programmed) 106191-01 106191-02 106191-03 Repair Kit Programmed Display Repair Kit 106217-04 (with Mounting Hardware) Repair Transformer Kit 106034-01 103448-10- 6/18...
  • Page 141 XIII. Repair Parts (continued) Part Number Description ALP080B ALP105B ALP150B ALP210B ALP285B Jacket, Rear/Bottom Panel 101217-01 101217-02 101217-03 101217-04 101217-05 Replacement Left Side Panel Kit (includes labels, access panels, grommets and header 105184-01 105184-02 105184-03 105184-04 105184-05 gaskets) Replacement Right Side Panel Kit 105183-01 105183-02 105183-03...
  • Page 142 XIII. Repair Parts (continued) Quantity Vent System Components Part Number ALP080B & ALP150B & ALP285B ALP105B ALP210B 2” Schedule 40 PVC Coupling Vent Terminal 101870-01 3” Schedule 40 PVC Coupling Vent Terminal 106680-01 4” Schedule 40 PVC Coupling Vent Terminal 106681-01 2”...
  • Page 143 XIII. Repair Parts (continued) Part Number Description ALP080B ALP105B ALP150B ALP210B ALP285B MISCELLANEOUS PARTS CARTON Temperature/Pressure Gauge 100282-01 External Gas Shutoff Valve 806SOL0005 101615-01 Safety Relief Valve 30 PSI: 81660363 30 PSI: 81660319 Alternate Safety Relief Valve (Not Shown) 50 PSI: 103837-01 Alternate Safety Relief Valve Kit (Not Shown, includes 80 PSI: 104200-01 safety relief valve and temperature &...
  • Page 144 XIII. Repair Parts (continued) Part Number Description ALP080B ALP105B ALP150B ALP210B ALP285B Vent Elbow w/Flue Sensor Port 102878-01 Rear Air Box 102867-01 Bottom Securing Bracket 102870-01 Hanging Bracket, Boiler 102868-01 Hanging Bracket, Wall 102869-01 Air Collar Plate Assembly 102871-02 Air Collar Plate Gasket 102876-01 Access Panel, Rear Air Box 102873-01...
  • Page 145 XIII. Repair Parts (continued) Part Number Description ALP080B ALP105B ALP150B ALP210B ALP285B Complete Wiring Harness (includes 10A, 10B, 10C & 10D) 102701-03 Main (Low Voltage) Harness 103009-03 High Voltage Harness 103010-02 Blower Power Harness 103012-01 Communication Harness 103011-01 Igniter Harness 105752-01 Wiring Harness, Thermal Link &...
  • Page 146 103448-10- 6/18...
  • Page 147 103448-10 - 6/18...
  • Page 148 U.S. Boiler Company, Inc. P.O. Box 3020 Lancaster, PA 17604 1-888-432-8887 www.usboiler.net 103448-10- 6/18...

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