U.S. Boiler Company ALTA-080 Installation, Operating And Service Instructions
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U.S. Boiler Company ALTA-080 Installation, Operating And Service Instructions

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ALTA
Installation, Operating and Service Instructions for
Models:
• ALTA-080
• ALTA-150
• ALTA-120
• ALTA-180
1.
Installer Read Before Proceeding . . . . . . . . . . .3
2.
3.
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .5
4.
How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
5.
Locating Boiler . . . . . . . . . . . . . . . . . . . . . . . . .10
6.
Preparing Boiler . . . . . . . . . . . . . . . . . . . . . . . .14
7.
General Venting . . . . . . . . . . . . . . . . . . . . . . . . .17
8.
Sidewall Direct Venting . . . . . . . . . . . . . . . . . . .24
9. Vertical Direct Venting . . . . . . . . . . . . . . . . . . .30
10. Heating System Piping . . . . . . . . . . . . . . . . . . .36
11. Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
12. Field Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
13. Condensate Disposal . . . . . . . . . . . . . . . . . . . .47
14. Start-Up and Checkout . . . . . . . . . . . . . . . . . .48
15. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
16. Before Leaving Jobsite . . . . . . . . . . . . . . . . . .67
17. Service and Maintenance . . . . . . . . . . . . . . . . .68
18. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . .72
19. Internal Wiring Diagrams . . . . . . . . . . . . . . . . .87
20. Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Appendix
D. Code Required Text . . . . . . . . . . . . . . . . . . . . .100
TO THE INSTALLER:
Affix these instructions adjacent to boiler.
Provide model number and serial number when
seeking information and support.
TO THE HOMEOWNER:
Retain these instructions for future reference.
Contact heating installer or technician for all issues
and support.
Version en Español disponible en el web del fabricante.
This boiler must only be installed, serviced, or repaired by a qualified installer, service agency or gas supplier.
Improper installation, adjustment, alteration, service or maintenance can cause severe personal injury, death,
or substantial property damage. For assistance or additional information, consult a qualified installer, service
agency, or the gas supplier. Read these instructions carefully before installing.
110328-04 - 2/23
• Water Boiler
• Condensing
• Direct Vent Models
• Gas Fired
Page
www.usboiler.net
!
WARNING

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Summary of Contents for U.S. Boiler Company ALTA-080

  • Page 1: Table Of Contents

    ALTA Installation, Operating and Service Instructions for • Water Boiler • Condensing • Direct Vent Models Models: • Gas Fired • ALTA-080 • ALTA-150 • ALTA-120 • ALTA-180 • ALTA-120B Manual Contents Page Installer Read Before Proceeding ...3 Homeowner Read Before Proceeding .
  • Page 2 ALTA Installation, Operating & Service Instructions The Massachusetts Board of Plumbers and Gas Fitters has listed the Alta Boiler. See the Massachusetts Board of Plumbers and Gas Fitters website for the latest Approval Code or ask your local Sales Representative. The Commonwealth of Massachusetts requires this product to be installed by a licensed Plumber or Gas fitter.

  • Page 3: Alta-120B Manual Contents Page 1. Installer Read Before Proceeding

    Installation, Operating & Service Instructions ALTA Installer or Qualified Service Agency Read Before Proceeding NOTICE: Size boiler properly relative to design WARNING heat load or, if using DHW priority, the peak Asphyxiation Hazard, Burn Hazard, Electrical hot water load, whichever is larger. A grossly Shock Hazard.

  • Page 4: Homeowner Read Before Proceeding

    ALTA Installation, Operating & Service Instructions User/Homeowner Read Before Proceeding NOTICE: Protect your home in freezing weather. WARNING A power outage, safety lockout, or component Asphyxiation Hazard. Fire Hazard. failure will prevent your boiler from lighting. In • A qualified installer, service agency or winter your pipes may freeze and cause extensive gas supplier should annually inspect boiler property damage.

  • Page 5: Specifications

    For altitudes above 2,000 ft. (610 m), ALTA-080 minimum input increased to 10 MBH. Table 3-2: Dimensions and Connections...
  • Page 6 Min Length ft. Max Length ft. Approx. Derate at Max. Length Model Number Intake/Vent Size in. (mm) Standard 2 (60) 2.5 (0.76) 70 (21.3) ALTA-080 w/ increaser 3 (80) 2.5 (0.76) 135 (41.1) Standard 2 (60) 2.5 (0.76) 70 (21.3)
  • Page 7 Crate W in. Crate H in. Content Surface Area ft Number (kg) (kg) (mm) (mm) (mm) gal (L) ALTA-080 107 (49) 71 (32) 41.4 (1050) 20.0 (508) 18.3 (465) 0.5 (1.9) 9.99 (0.9) ALTA-120 112 (51) 76 (35) 41.4 (1050) 20.0 (508)

  • Page 8: How It Works

    ALTA Installation, Operating & Service Instructions How It Works 1. Heat exchanger 9. Control enclosure Water flows through heat exchanger's stainless Houses boiler control and provides access to steel tubes. Heat is transferred to water as flue installed fuses and spare fuses. products are cooled below point of condensation 10.
  • Page 9 Installation, Operating & Service Instructions ALTA How It Works (continued) Figure 4-1: How It Works 110328-04 - 2/23...

  • Page 10: Locating Boiler

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

  • Page 14: Preparing Boiler

    ALTA Installation, Operating & Service Instructions Preparing Boiler Unpack Boiler CAUTION Remove boiler and parts carton from outer shipping Heavy Object. carton. Boiler weighs up to 130 lb (59 kg). Two people are required to lift boiler onto wall mounting CAUTION bracket.
  • Page 15 Installation, Operating & Service Instructions ALTA Preparing Boiler (continued) Attach with Install Vent Connector (4) screws 1. Remove vent connector and screws from parts Vent Connector carton. 2. Check vent reducer on top of heat exchanger to ensure it is installed properly. Flue gas sample port facing front of boiler...
  • Page 16 ALTA Installation, Operating & Service Instructions Preparing Boiler (continued) 3. For wood studs, drill 3/16 in. (4.8 mm) pilot holes Mount Boiler "A" and "B" and attach bracket using provided 1. Wall bracket is designed to mount on studs 5/16 in. x 2 in. lag screws and washers. For wood with 16 in.

  • Page 17: General Venting

    Installation, Operating & Service Instructions ALTA General Venting Direct Vent Sidewall Termination Options Figure 7-2: Sidewall Low Figure 7-3: Sidewall Figure 7-1: Sidewall Profile Termination - see Concentric Termination - Termination with Fittings - Section 8 for details see Section 8 for details see Section 8 for details Direct Vent Vertical Termination Options Figure 7-4: Vertical...
  • Page 18 ALTA Installation, Operating & Service Instructions General Venting (continued) 1. Min and max lengths are calculated separately for air and vent. For example, max length 135 ft. (41.1 Vent and Air Sizing m) means up to 135 ft. (41.1 m) air piping and up to 135 ft.
  • Page 19 Installation, Operating & Service Instructions ALTA General Venting (continued) 5. Example equivalent length calculation for 2 in. NOTICE: PVC may not be used to penetrate vent: combustible or non-combustible walls unless all A. 1 ft. CPVC straight pipe =1 eq ft. of the following conditions are met.
  • Page 20 ALTA Installation, Operating & Service Instructions General Venting (continued) in connector. Insert pipe into air connector and use #10 x 1 in. sheet metal screw to secure. Seal 6. CPVC/PVC vent starter kits are available. Kits joint between air connector and pipe with RTV include 30 in.
  • Page 21 Installation, Operating & Service Instructions ALTA General Venting (continued) Maximum Wall 2"* 6" 12" Thickness ("T") (50mm) (150mm) (305mm) Minimum air space 0"* 1" 1-3/4" around pipe ("C") (0mm) (25mm) (45mm) One end of opening may *Wall must be of non-combustible construction be closed PVC Vent Pipe 66"...
  • Page 22 ALTA Installation, Operating & Service Instructions General Venting (continued) Polypropylene Venting Table 7-16: Listed Polypropylene Vent Materials (ULC-S636 Listed) WARNING Manufacturer Model Asphyxiation Hazard. Polypropylene Single Wall Rigid • Use only vent materials listed in Table 7-16 DuraVent to make vent connections. Consult vent PolyPro Flex manufacturer's instructions for required support InnoFlue Single Wall Rigid...
  • Page 23 Installation, Operating & Service Instructions ALTA General Venting (continued) Table 7-17: Listed Polypropylene Vent Fittings DuraVent Length Centrotherm InnoFlue Selkirk PolyFlue PolyPro 2 in. (60 mm) 2PPS-LC IANS02 PF-LB Joint Connector 3 in. (80 mm) 3PPS-LC IANS03 PF-LB or 4PF-LB 2 in.

  • Page 24: Sidewall Direct Venting

    ALTA Installation, Operating & Service Instructions Sidewall Direct Venting Determine Terminal Location C. Minimum 12 in. (305 mm) from inside corner. 6 ft. (1.8 m) is generally recommended and WARNING required when window and/or air inlet is within Asphyxiation Hazard. 4 ft.
  • Page 25 Installation, Operating & Service Instructions ALTA Sidewall Direct Venting (continued) 110328-04 - 2/23...
  • Page 26 ALTA Installation, Operating & Service Instructions Sidewall Direct Venting (continued) Table 8-3: Polypropylene Sidewall Terminal Fittings CPVC/PVC or Polypropylene Fittings DuraVent Centrotherm Terminal Selkirk PolyFlue PolyPro InnoFlue WARNING UV resistant UV stabilized UV resistant Asphyxiation Hazard. single wall pipe end pipe + two pipe + two 2PF- All CPVC/PVC vent joints must be glued.
  • Page 27 Installation, Operating & Service Instructions ALTA Sidewall Direct Venting (continued) Table 8-7: CPVC/PVC Low Profile Terminal Kits DuraVent & Selkirk: Remove gasket to Length Ipex Diversitech install screen From boiler 2 in. (60 mm) 397984 HVENT-2 Elbow vent connection 3 in. (80 mm) 397985 HVENT-3 To boiler...
  • Page 28 ALTA Installation, Operating & Service Instructions Sidewall Direct Venting (continued) CPVC/PVC Concentric Terminal 3. Follow terminal manufacturer's instructions and Figure 8-11 for assembly. WARNING 4. If needed, terminal can be shortened. Follow Asphyxiation Hazard. terminal manufacturer's instructions and Figure All CPVC/PVC vent joints must be glued. Failure 8-12.
  • Page 29 Installation, Operating & Service Instructions ALTA Sidewall Direct Venting (continued) Kit Size *'A' Manufacturer 7-3/8" (187mm) 1-3/4" (44mm) *Overall length of inner IPEX 3-1/2" (89mm) 2" pipe to be 'A' longer than overall 12-3/16" (310mm) 3/4" (19mm) DIVERSITECH length of outer pipe. 8-3/4"...

  • Page 30: Vertical Direct Venting

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

  • Page 36: Heating System Piping

    ALTA Installation, Operating & Service Instructions Heating System Piping General System Piping Precautions B. Pipe outlet of safety relief valve to location where water or steam will not create a WARNING hazard or cause property damage if valve Asphyxiation Hazard. opens.
  • Page 37 Required inch, FPT inch, FPT Flow Loss, Flow Loss, Loss, Flow Loss, Flow (GPM) (GPM) (Ft.) (GPM) (Ft.) (Ft.) (GPM) (Ft.) ALTA-080 13.1 19.8 ALTA-120 11.2 14.6 20.0 11.2 29.7 ALTA-120B ALTA-150 10.9 11.3 15.3 14.1 23.4 ALTA-180 11.6 11.3 15.5...
  • Page 38 ALTA Installation, Operating & Service Instructions Heating System Piping (continued) 3. Fill valve (required) 9. Drain valve (required) A. Either a manual or automatic fill valve may Install drain valve as shown in Figures 10-3 be used, but a manual valve is preferred and 10-4.
  • Page 39 Installation, Operating & Service Instructions ALTA Heating System Piping (continued) 110328-04 - 2/23...
  • Page 40 ALTA Installation, Operating & Service Instructions Heating System Piping (continued) 110328-04 - 2/23...
  • Page 41 Installation, Operating & Service Instructions ALTA Heating System Piping (continued) Figure 10-5: Near Boiler Piping Supplied with Boiler 110328-04 - 2/23...

  • Page 42: Gas Piping

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

  • Page 43: Field Wiring

    Installation, Operating & Service Instructions ALTA Field Wiring Locating Field Connection Terminal Strips DANGER Field connection terminal strip locations are shown in Electrical Shock Hazard. • Disconnect electrical supply before Figure 12-1. To access terminal strips: installing or performing maintenance. 1.
  • Page 44 ALTA Installation, Operating & Service Instructions Field Wiring (continued) D. Maximum combined current draw for all circulators is 5A. Low Voltage Connections 1. All low voltage field connections to boiler are made on Low Voltage Connections terminal strip (see Figure 12-3) located on left side of bottom panel.
  • Page 45 Installation, Operating & Service Instructions ALTA Field Wiring (continued) i. Refer to Section 10 Heating System Piping 2. External power must not be applied to any low for LWCO kits available from manufacturer. voltage terminals - doing so may damage boiler control.
  • Page 46 ALTA Installation, Operating & Service Instructions Field Wiring (continued) Figure 12-5: TACO SR504 or Equivalent Zone Panel Wiring Connection Diagram 110328-04 - 2/23...

  • Page 47: Condensate Disposal

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

  • Page 48: Start-Up And Checkout

    ALTA Installation, Operating & Service Instructions Start-Up and Checkout Heating System Cleaning and Treatment Fill Water Quality CAUTION NOTICE: Make sure system is filled with water meeting Component Damage. the following criteria: Proper flushing, cleaning, and water side • Hardness less than 7 grains/gallon. maintenance is highly recommended to protect •...
  • Page 49 Installation, Operating & Service Instructions ALTA Start-Up and Checkout (continued) Final Check Before Starting Boiler A. Use 1/4 in. (6 mm) ID tubing connected to hose barb and route tubing to a safe draining location. WARNING B. Turn vent counter clockwise and allow heat Asphyxiation Hazard.
  • Page 50 ALTA Installation, Operating & Service Instructions Start-Up and Checkout (continued) LP Conversion 3. Use keypad to enter adjust mode and change parameter A06 from "0" to "1". WARNING Press and hold "menu" for 3 seconds. • Asphyxiation Hazard. Press "" or "" buttons until PAS is visible •...
  • Page 51 Installation, Operating & Service Instructions ALTA Start-Up and Checkout (continued) Final Check Before Starting Boiler 7. If successful ignition, display will show flame icon (continued) (Figure 14-7). 1. Start boiler using lighting instructions in Figure 14-9. With boiler powered up, and with no call for heat, display should look like Figure 14-4.
  • Page 52 ALTA Installation, Operating & Service Instructions Start-Up and Checkout (continued) 10. Perform combustion test. WARNING Asphyxiation Hazard. Use a combustion analyzer to verify proper operation by checking carbon monoxide (CO) levels. Failure to use a combustion analyzer could cause operation of boiler with elevated CO levels resulting in severe personal injury, death or substantial property damage.
  • Page 53 Installation, Operating & Service Instructions ALTA Start-Up and Checkout (continued) FOR YOUR SAFETY READ BEFORE OPERATING/POUR VOTRE × × × × SECURITE LISEZ AVANT DE METTRE EN MARCHE WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.
  • Page 54 ALTA Installation, Operating & Service Instructions Start-Up and Checkout (continued) Boiler Sequence of Operation Table 14-10: Boiler Sequence of Operation Status Screen Display Description Burner - Off Pump(s) - Off Priority: Standby There is no call for heat, boiler is not firing and priority is "standby". Boiler is ready to Status: respond to a call for heat.

  • Page 55: Operation

    Installation, Operating & Service Instructions ALTA Operation User Display Overview reset – Figure 15-1: Display Icons Table 15-2: Display Descriptions When not flashing or alternating display temperature is 180°F boiler supply temperature. Visible when Central Heat demand is present. Visible when DHW demand is present. Icon will flash if DHW setpoint is being adjusted.
  • Page 56 ALTA Installation, Operating & Service Instructions Operation (continued) Operating Mode The STA (status) display code contains below listed Basic boiler status is displayed and DHW setpoint values. may be adjusted. Table 15-5 Managing of Status Numbers Description (see Section 18 reset Display Troubleshooting for explanation)
  • Page 57 Installation, Operating & Service Instructions ALTA Operation (continued) Adjust Mode Menu Diagnostic information and Quick Menu parameters are available without entering a password. Press and Hold “menu” button for 3 seconds to access Adjust Mode. reset Press Press buttons buttons to view next to adjust –...
  • Page 58 ALTA Installation, Operating & Service Instructions Operation (continued) Accessing Password Protected Menus Password protected parameters are available by entering a password. Press and hold the "menu" for 3 seconds, reset Press "" or "" buttons until PAS is visible and press "enter". Press "enter"...
  • Page 59 Installation, Operating & Service Instructions ALTA Operation (continued) Table 15-11: Menu A A , Quick Menu (items A06, A07, A08 and A09 visible only after password entered) Range/ Default Parameter and Description Choices A01 Boiler On/Off Switch On/Off Boiler switch allows an installer to prevent boiler starts while boiler powered and reviewing boiler settings.
  • Page 60 ALTA Installation, Operating & Service Instructions Operation (continued) Table 15-12: Menu FR FR, Firing Rate (visible only after password entered) Default Range/ Choices Parameter and Description F01 Manual Modulation Enable Setting to "On" allows technician to fire at rate specified in F02. To return to Auto change setting to "Off".
  • Page 61 Installation, Operating & Service Instructions ALTA Operation (continued) Table 15-13: Menu 5P 5P, , Setpoint Menu (visible only after password entered) Range/ Default Parameter and Description Choices 501 Temperature Units Sets display temperature in degrees Fahrenheit or Celsius. 0, 1 Fahrenheit Celsius 502 DHW Priority Time...
  • Page 62 ALTA Installation, Operating & Service Instructions Operation (continued) Table 15-15: Menu PU PU, Pump Menu (visible only after password entered) Range/ Default Parameter and Description Choices P01 System Pump Output Select: Activates System Pump output according to selected function. System Pump Any Pump Runs during any call for heat.
  • Page 63 Installation, Operating & Service Instructions ALTA Operation (continued) Table 15-16: Menu LL LL, Lead Lag Menu (visible only after password entered) Range/ Default Parameter and Description Choices L01 Lead Lag Master Enable Used to "turn on" Multiple Boiler Controller On/Off Sequencer Master is Enabled.
  • Page 64 ALTA Installation, Operating & Service Instructions Operation (continued) NOTICE: This section covers control features available via local display. For additional control features available via our App, see Extended Features manual available on our website or in our App. Control System Overview 6.
  • Page 65 Installation, Operating & Service Instructions ALTA Operation (continued) Table 15-18: Order of Priority 2. High Differential Temperature Limit Control monitors temperature difference between Boiler Responding to: return and supply sensors. If this difference Domestic Hot Water exceeds 58°F (32°C) control begins to reduce 2nd Sequencer Control blower maximum speed and if temperature Connected to the peer-to-peer network.
  • Page 66 ALTA Installation, Operating & Service Instructions Operation (continued) Boiler Protection Features (continued) 11. Central Heating System Frost Protection 7. Flue High Limit Frost Protection starts boiler and system pump Control monitors flue gas temperature sensor and fires boiler when low outdoor air, low supply located at top of heat exchanger.

  • Page 67: Before Leaving Jobsite

    Installation, Operating & Service Instructions ALTA Before Leaving Jobsite Before leaving jobsite Installed wall retaining clips (bottom)  Flushed heating system  Boiler and system filled with water  Air purged from boiler system  No loose, uninsulated or miswired connections ...

  • Page 68: Service And Maintenance

    ALTA Installation, Operating & Service Instructions Service and Maintenance Important Product Safety Information: Refractory Ceramic Fiber Product WARNING Some boiler components use materials that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to elevated temperatures, RCF may change into crystalline silica, a known carcinogen.
  • Page 69 Installation, Operating & Service Instructions ALTA Monthly Inspections: Service and Maintenance (continued) 1. Inspect vent piping and air intake piping to verify it is free from leakage and deterioration. Also verify vent and air intake terminals are WARNING unobstructed. Asphyxiation Hazard. Fire Hazard. Explosion Hazard.
  • Page 70 ALTA Installation, Operating & Service Instructions D. Verify gap between ignitor/flame sensor and Service and Maintenance (continued) burner is within range shown in Figure 17-3 and Table 17-4. Ignitor/Flame Sensor Gap "A" Burner Door Mounting Nuts (4X) Figure 17-3: Ignitor/Flame Sensor to Burner Gap Figure 17-1: Ignitor/Flame Sensor Location Table 17-4: Electrode Gap 4.
  • Page 71 Installation, Operating & Service Instructions ALTA Service and Maintenance E. Refer to Sections 7 thru 9 to re-assemble (continued) any vent system components that are disassembled during this inspection and for details on supporting, pitching and terminating vent system. Condensate Tube from heat exchanger 12.

  • Page 72: Troubleshooting

    ALTA Installation, Operating & Service Instructions Troubleshooting WARNING Electrical Shock Hazard. Turn off power to boiler before working on wiring. A. Troubleshooting with No Active Fault Code Displayed Table 18-1: Troubleshooting with No Active Fault Code Indication Possible Causes Corrective Action Display Completely Check breaker and wiring between breaker panel and No 120 VAC supplied to boiler.
  • Page 73 Installation, Operating & Service Instructions ALTA Troubleshooting (continued) In event of high CO (CO air free greater than 200 ppm for 0-2,000 ft. (0-160 m) or greater than 300 ppm for above 2,000 ft. (610 m)) follow below steps in specified order: 1.
  • Page 74 ALTA Installation, Operating & Service Instructions Troubleshooting (continued) B. Troubleshooting with Status Numbers In Operating Mode, use arrow keys ("" or "") to reach "StA". Display will then alternate between "StA" and number shown below. Table 18-2: Status Number Explanation Display Description Explanation...
  • Page 75 Installation, Operating & Service Instructions ALTA Troubleshooting (continued) C. Troubleshooting with Diagnostic Codes In Diagnostic and Quick Menu Mode, use the arrow keys ("" or "") to reach "c" menu and press "enter" button to view diagnostic codes. Table 18-3: Diagnostic Menu Display Name Description...
  • Page 76 ALTA Installation, Operating & Service Instructions Troubleshooting (continued) D. Troubleshooting with Active Fault Code. Control uses following codes to describe abnormal operation: Table 18-4: Lockout/Hold/Warning Symbol Description Code Type Boiler Status Description When a lockout occurs, boiler will shut down and event is stored in history, b, menu.
  • Page 77 Installation, Operating & Service Instructions ALTA Troubleshooting (continued) Table 18-5: Active Fault Code and Corrective Actions (continued) Detailed Fault Code found on "b" and "c" menus in brackets, e.g. [1.0]. Code Name Possible Cause Corrective Action Verify the system is full of water and the air has been properly purged.
  • Page 78 ALTA Installation, Operating & Service Instructions Troubleshooting (continued) Table 18-5: Active Fault Code and Corrective Actions (continued) Detailed Fault Code found on "b" and "c" menus in brackets, e.g. [1.0]. Code Name Possible Cause Corrective Action Inspect heat exchanger and clean flue side of heat Heat exchanger dirty.
  • Page 79 Installation, Operating & Service Instructions ALTA Troubleshooting (continued) Table 18-5: Active Fault Code and Corrective Actions (continued) Detailed Fault Code found on "b" and "c" menus in brackets, e.g. [1.0]. Code Name Possible Cause Corrective Action • Remove jumper from air proving switch. Defective air proving •...
  • Page 80 ALTA Installation, Operating & Service Instructions Troubleshooting (continued) Table 18-5: Active Fault Code and Corrective Actions (continued) Detailed Fault Code found on "b" and "c" menus in brackets, e.g. [1.0]. Code Name Possible Cause Corrective Action [18.0] Application Normal condition following a parameter download, set Factory parameters are not valid.
  • Page 81 Installation, Operating & Service Instructions ALTA Troubleshooting (continued) Table 18-5: Active Fault Code and Corrective Actions (continued) Detailed Fault Code found on "b" and "c" menus in brackets, e.g. [1.0]. Code Name Possible Cause Corrective Action No gas, insufficient gas supply Verify no air in gas line.
  • Page 82 ALTA Installation, Operating & Service Instructions Troubleshooting (continued) Table 18-5: Active Fault Code and Corrective Actions (continued) Detailed Fault Code found on "b" and "c" menus in brackets, e.g. [1.0]. Code Name Possible Cause Corrective Action Hardware Fault Control damaged. Check control, cycle power, replace if necessary.
  • Page 83 Installation, Operating & Service Instructions ALTA Troubleshooting (continued) Table 18-6: Detailed Fault Code (found on "c" and "b" menus) Detailed Code Type Condition Code Anti-short cycle boiler start delay, while thermostat demand present, boiler has H01.0 Warning cycled off and restart is delayed. Urgent calibration cooling delay.
  • Page 84 ALTA Installation, Operating & Service Instructions Troubleshooting (continued) Table 18-6: Detailed Fault Code (found on "c c " and "b b " menus, continued) Detailed Code Type Condition Code H17.0 Hold Control in program mode. H17.1 Hold Internal Safety Core error. E17.2 Lockout Parameter CRC error.
  • Page 85 Installation, Operating & Service Instructions ALTA Troubleshooting (continued) Table 18-6: Detailed Fault Code (found on "c c " and "b b " menus, continued) Detailed Code Type Condition Code H24.0 Warning Flame signal loss in operation. H24.1 Hold Flame signal loss in stabilization phase. H24.2 Hold Flame signal loss in safety time.
  • Page 86 ALTA Installation, Operating & Service Instructions Troubleshooting (continued) Table 18-7: Supply, Return, Header and Flue Table 18-8: Outdoor Air Temperature Sensor Temperature Sensor Temperature versus Temperature versus Resistance (10 kOhm) Resistance (10 kOhm) Outdoor Temperature Ohms of Temperature Ohms of Resistance °F °C...

  • Page 87: Internal Wiring Diagrams

    Installation, Operating & Service Instructions ALTA Internal Wiring Diagrams Figure 19-1: Ladder Diagram 110328-04 - 2/23...
  • Page 88 ALTA Installation, Operating & Service Instructions Internal Wiring Diagrams (continued) 110328-04 - 2/23...
  • Page 89 Installation, Operating & Service Instructions ALTA Internal Wiring Diagrams (continued) 110328-04 - 2/23...

  • Page 90: Service Parts

    All service parts may be obtained through your local U.S. Boiler Company Wholesale distributor. Should you require assistance in locating a U.S. Boiler Company Distributor in your area, or have questions regarding the availability of U.S. Boiler Company products or service parts, please contact us at 1-888-432-8887 or Fax (717) 481-8408 or at www.usboiler.net.
  • Page 91 Installation, Operating & Service Instructions ALTA Service Parts (continued) (120 MBH) (80 & 150/180 MBH) Part Number Key No. Description ALTA-080 ALTA-120 ALTA-120B ALTA-150 ALTA-180 10A, 10B Water Pipe Gaskets 110577-01 11A, 11B Water Pipes (w/ gaskets) 111561-01 111562-01 111561-01 Return Temp.
  • Page 92 ALTA Installation, Operating & Service Instructions Service Parts (continued) Part Number Key No. Description ALTA-080 ALTA-120 ALTA-120B ALTA-150 ALTA-180 23, 28, 30, 50, Blower (with gaskets, o-rings, 110586-01 111571-01 51, 52, 53, and hardware) 24A, 24B, 24C, Gas Valve (with gaskets,...
  • Page 93 Installation, Operating & Service Instructions ALTA Service Parts (continued) Part Number Key No. Description ALTA-080 ALTA-120 ALTA-120B ALTA-150 ALTA-180 31A, 31B, 31C, 31D, 31E, Condensate Trap 110589-01 31F, 31G, 31H Front Door 110595-01 Vent connector 107160-01 Side panel 110725-01 111565-01...
  • Page 94 ALTA-120B ALTA-150 ALTA-180 Control Enclosure 111597-01 Boiler Control 111971-01 Contact U.S. Boiler Company; Provide boiler serial number Model Key 120 VAC Connection Board 110726-01 Low Voltage Connection Board 110594-01 Fuse, 0.5A, 5 x 20 mm, 250V, Slow Blow Fuse, 1.0A, 5 x 20 mm, 250V, Slow Blow 111420-01 Fuse, 5.0A, 5 x 20 mm, 250V, Slow Blow...
  • Page 95 Installation, Operating & Service Instructions ALTA Service Parts (continued) Part Number Key No. Description ALTA-080 ALTA-120 ALTA-120B ALTA-150 ALTA-180 Ignition Harness 110598-01 Main Control Harness 111566-01 Power Harness Part Number Accessories Description ALTA-080 ALTA-120 ALTA-120B ALTA-150 ALTA-180 2 in. CPVC/PVC Vent Kit 107039-01 3 in.

  • Page 96: Combination Refrigeration/Heating System

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

  • Page 97: Water Quality And Boiler Additives

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

  • Page 98: Special Requirements In Massachusetts

    ALTA Installation, Operating & Service Instructions Appendix C Special Requirements For Side-Wall Vented Appliances In The Commonwealth of Massachusetts IMPORTANT The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4.00 and 5.00 for installation of side-wall vented gas appliances as follows: (a) For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) ft.
  • Page 99 Installation, Operating & Service Instructions ALTA Appendix C Special Requirements For Side-Wall Vented Appliances In The Commonwealth of Massachusetts (continued) (c) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED. When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall include:1.

  • Page 100: Code Required Text

    ALTA Installation, Operating & Service Instructions Appendix D Code Required Text See Section 5 Locating Boiler: Remove Existing Boiler 6. Une fois qu'il a été déterminé, selon la méthode indiquée ci-dessus, que chaque for context of following text: appareil raccordé au système d'évacuation Les instructions doivent comprendre le mode est mis à...
  • Page 101 Installation, Operating & Service Instructions ALTA SERVICE RECORD DATE SERVICE PERFORMED 110328-04 - 2/23...
  • Page 102 ALTA Installation, Operating & Service Instructions SERVICE RECORD DATE SERVICE PERFORMED 110328-04 - 2/23...
  • Page 103 Installation, Operating & Service Instructions ALTA SERVICE RECORD DATE SERVICE PERFORMED 110328-04 - 2/23...
  • Page 104 ALTA Installation, Operating & Service Instructions U.S. Boiler Company, LLC P.O. Box 3020 Lancaster, PA 17604 1-888-432-8887 www.usboiler.net 110328-04 - 2/23...

This manual is also suitable for:

Alta-150Alta-120Alta-180Alta-120b

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