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Energy Star ALPINE Installation, Operating And Service Instructions

Alpine series condensing high efficiency direct vent gas - fired hot water boiler
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As an ENERGY STAR
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guidelines for energy efficiency established by the United States Environmental Protection Agency (EPA).
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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.
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Partner, U.S. Boiler Company has determined that the Alpine™ Series meets the ENERGY
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Price - $5.00

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  • Page 1 ™ 9700609 As an ENERGY STAR Partner, U.S. Boiler Company has determined that the Alpine™ Series meets the ENERGY ® STAR guidelines for energy efficiency established by the United States Environmental Protection Agency (EPA). ® Warning: Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury, or loss of life.
  • Page 2 The City of New York requires a Licensed Master Plumber supervise the installation of this product. The Massachusetts Board of Plumbers and Gas Fitters has approved the Alpine™ Series boiler. See the Massachusetts Board of Plumbers and Gas Fitters website, http://license.reg.state.ma.us/pubLic/pl_products/pb_pre_form.asp for the latest Approval Code or ask your local Sales Representative.
  • Page 3 Special Installation Requirements for Massachusetts A. For all sidewall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes and where the sidewall exhaust vent termination is less than seven (7) feet above grade, the following requirements shall be satisfied: 1.
  • Page 4 Warning 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 5: Table Of Contents

    TABLE OF CONTENTS Product Description, Specifications and Dimensional Data...... Unpacking Boiler..................11 III. Pre-Installation and Boiler Mounting ............Venting...................... A. General Guidelines................19 B. CPVC/PVC Venting................22 C. Polypropylene Venting................. 31 D. Stainless Steel Venting................ 37 E. Concentric Polypropylene Venting............39 F.

  • Page 6: Product Description, Specifications And Dimensional Data

    I. Product Description, Specifications and Dimensional Data Alpine™ Series boilers are condensing high efficiency for Construction of Heating Boilers’ of ASME Boiler and gas-fired direct vent hot water heating boilers designed Pressure Vessel Code, which provide a maximum heat for use in forced hot water space or space heating with...
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  • Page 10 I. Product Description, Specifications and Dimensional Data (continued) Table 2a: rating Data - Models aLP080B thru aLP399 (0 to 2000 Feet Elevation above Sea Level) alpine Series gas-Fired Boilers Input (MBH) Boiler Water Heat Transfer Area * Model Number Volume (Gal.) (Sq.

  • Page 11: Unpacking Boiler

    I. Product Description, Specifications and Dimensional Data (continued) Table 2C: rating Data - Models aLP150B thru aLP285B (7001 to 10,000 Feet Elevation above Sea Level) alpine Series gas-Fired Boilers Input (MBH) Boiler Water Heat Transfer Area Model Number * Volume (Gal.) (Sq.

  • Page 12: Pre-Installation And Boiler Mounting

    Do not install boiler on General. carpeting. 1. Alpine boilers are intended for installations in an Provide clearance between boiler jacket and area with a floor drain or in a suitable drain pan to combustible material in accordance with local fire prevent any leaks or relief valve discharge to cause ordinance.
  • Page 13 2 x 4’s anchored to the studs. boiler carton. CaUTiOn CaUTiOn alpine boiler approximate dry weights: The outer edges of the template represent aLP080BW – 98 lbs; aLP105BW – 112 lbs; minimum side, top and bottom clearances to aLP150BW – 136 lbs: aLP210BW – 150 lbs combustible material.
  • Page 14 iii. Pre-installation and Boiler Mounting G. General (continued) Figure 2a: Clearances To Combustible and non-combustible Material, Floor Standing Figure 2B: Clearances To Combustible and non-combustible Material, Wall Mounted 103448-02 - 6/13...
  • Page 15 iii. Pre-installation and Boiler Mounting G. General (continued) m. See Section IV Venting; Paragraph B, 5 “Field n. After the boiler has been piped, wired, connected Installation of CPVC Vent Pipe - Wall Mounted to vent and combustion air system piping and Boiler Builds”...
  • Page 16 iii. Pre-installation and Boiler Mounting G. General (continued) 16" C/C WALL BRACKET BOILER HANGING BRACKET BOILER #8 X " SMS (2X) BOILER HANGING BRACKET BOILER BOTTOM SECURING BRACKET 2 X 4 WALL STUD " X 2" LAG SCREW (4X) BOTTOM SECURING BRACKET "...
  • Page 17 (ALP) boilers may be installed stacked one on the top of the other. Refer to Table 3 “Alpine (ALP) top and bottom boiler left side panels with Boiler Model Stacking Combinations” for details.
  • Page 18 iii. Pre-installation and Boiler Mounting H. Boiler Stacking (continued) condensate disposal. Terminating individual c. Water Piping and Trim - Follow instructions boiler condensate lines into common pipe prior in Section VI “Water Piping and Trim” of the to drain disposal is permissible, providing manual for system piping and boiler secondary common pipe has sufficient flow capacity piping selection/sizing based on combined...

  • Page 19: Venting

    Concentric Inner Polypropylene Vent restrictions and installation inspection in your area. and Outer Steel Combustion Air System 2. The Alpine™ is designed to be installed as a - the assembly consists of inner fire resistant Direct Vent (sealed combustion) boiler. The air...
  • Page 20 iV. Venting A. General Guidelines (continued) Table 4: Vent/Combustion air System Options approved Direct Boiler Vent Component Orientation Termination Description Figures Part Vent System Mounting Material Table The system includes separate CPVC vent pipe and PVC air intake Standard pipe terminating thru sidewall with 5 thru 10 (thru sidewall) individual penetrations for the vent...
  • Page 21 iV. Venting A. General Guidelines (continued) Figure 4: Location of Vent Terminal relative to Windows, Doors, grades, Overhangs, Meters and Forced air inlets (Concentric Terminal Shown - Two-Pipe System Vent Terminal to be installed in same location - Two-Pipe System air intake Terminal not Shown) b.

  • Page 22: Cpvc/Pvc Venting

    iV. Venting A. General Guidelines (continued) CPVC/PVC Venting n. If possible, install the vent and air intake terminals Warning on a wall away from the prevailing wind. Reliable operation of this boiler cannot be guaranteed if the CPVC vent components must be used within any terminal is subjected to winds in excess of 40 mph.
  • Page 23 iV. Venting B. CPVC/PVC Venting (continued) d. Follow all manufacturer instructions and b. Align vent connector plate and gasket clearance warnings when preparing pipe ends for joining holes with rear/bottom panel engagement holes; and using the primer and the cement. than, secure the connector and gasket to the Field Installation of CPVC/PVC Two-Pipe panel with six mounting screws.
  • Page 24 iV. Venting B. CPVC/PVC Venting (continued) Table 5C: CPVC/PVC Vent & Air Intake Components (Installer Provided) required for Optional Vertical (roof) Termination Quantity aLP080B & aLP150B & aLP285B thru Part Vent Components aLP105B aLP210B aLP399 number Vertical (roof) Vertical (roof) Vertical (roof) Termination Termination...
  • Page 25 iV. Venting B. CPVC/PVC Venting (continued) OFFSET CHANGE OF DIRECTION (VERTICAL OR HORIZONTAL) LONG RUN OF PIPE LOOP LENGTH RESTRAINT (RESTRICTS MOVEMENT) HANGER (ALLOWS MOVEMENT) Table 7: Expansion Loop Lengths LOOP (HORIZONTAL ONLY) nominal Length of Loop Length (TOP VIEW) Pipe Dia.
  • Page 26 iV. Venting B. CPVC/PVC Venting (continued) Table 8: Vent/Combustion air Pipe Length – Two-Pipe Direct Vent System Options • CPVC/PVC • Polypropylene (PP) or Polypropylene (PP)/PVC • Stainless Steel/PVC or Galvanized Steel) 3” (80 mm) 4” (100 mm) 3” (80 mm) Vent Pipe 4”...
  • Page 27 iV. Venting B. CPVC/PVC Venting (continued) Figure 7a: near-Boiler Vent/Combustion air Piping - Floor Mounted Boiler Builds ii. The factory supplied CPVC vent pipe (3” Schedule 40 x 30” long CPVC pipe) must be used for near-boiler piping before transitioning to Schedule 40 PVC (ASTM 2665) pipe components for reminder of vent system.
  • Page 28 iV. Venting B. CPVC/PVC Venting (continued) b. Optional Two-Pipe Snorkel Termination See Figures 10 and 11. This installation will allow a maximum of seven (7) feet vertical exterior run of the vent/combustion air piping to be installed on the CPVC/PVC horizontal venting application.
  • Page 29 iV. Venting B. CPVC/PVC Venting (continued) Vertical Vent Termination a. Standard Two-Pipe Termination Refer to Figures 8, 10, 12 and 13. Vent Piping • Install fire stops where vent passes through floors, ceilings or framed walls. The fire stop must close the opening between the vent pipe and the structure.
  • Page 30 iV. Venting B. CPVC/PVC Venting (continued) • Install Rodent Screen and Vent Terminal (supplied with boiler), see Figure 10 for appropriate configuration. • Brace exterior piping if required. Combustion Air Piping • Locate combustion air termination on the same roof location as the vent termination to prevent nuisance boiler shutdowns.

  • Page 31: Polypropylene Venting

    Polypropylene Vent Installation Instructions provided with Polypropylene Venting a manufacturer specific kits. See Tables 9 and 10 below. Alpine boilers have been approved for use with Refer to Table 8 ‘Vent/Combustion Air Pipe Length – polypropylene vent system. Two-Pipe Direct Vent System Options’ for minimum and It is an installing contractor responsibility to procure maximum listed equivalent length values.
  • Page 32 Do not install flexible polypropylene pipe at an Piping – Floor Mounted Boiler Builds: angle greater than 45 degrees from vertical plane Alpine floor mounted boilers are factory supplied with a when used for combustion product venting. model-specific boiler two-pipe CPVC/PVC vent system...
  • Page 33 iV. Venting C. Polypropylene Venting (continued) Figure 15: Field installation Procedure to accept Polypropylene Vent Piping - Wall Mounted Boiler 6) Install boiler adapter connector PPS-PAC to secure PVC to PP boiler adapter to the vent connection port of boiler two-pipe system connector. 7) Attach modified two-pipe system adapter to boiler.
  • Page 34 30” long CPVC pipe exposed end. Mounted Boiler Builds: 18) If using polypropylene pipe for combustion air Alpine wall mounted boiler builds have a factory installed intake, attach and cement an appropriate diameter vent connector 90° elbow inside air box and air box top PVC coupling (contractor supplied) to exposed end located combustion air collar, See Part B ‘CPVC/PVC...
  • Page 35 Chase or Adjacent Flues Prohibited! running Flexible Polypropylene Vent (Liner) Thru Unused Chimney Chase (see Figure 16). Alpine boilers are approved for vertical venting by installing Flexible Vent in an UNUSED masonry chimney/chase and supplying combustion air thru a separate wall or roof air intake terminal.
  • Page 36 iV. Venting C. Polypropylene Venting (continued) Warning Follow installation instructions included by the original polypropylene venting component manufacturers, M&g/DuraVent or Centrotherm, whichever applicable. Flexible Polypropylene Vent must be installed in an UnUSED chimney. a chimney, either single or multiple flue type, is considered UNUSED when none of the flues is being used for any appliance venting.

  • Page 37: Stainless Steel Venting

    iV. Venting D. Stainless Steel Venting (continued) Stainless Steel Venting CaUTiOn Vent systems made by Heat Fab, Protech and Z-Flex rely on gaskets or proper sealing. When these vent systems are used, take the following precautions: • Make sure that gasket is in position and un- damaged in the female end of the pipe.
  • Page 38 iV. Venting D. Stainless Steel Venting (continued) Table 13B: alternate Vent Systems and Vent Components (Stainless Steel) Vent Vertical Manufacturer Size Wall Thimbles Horizontal Termination System Termination Protech FSWT3 Tee: FSTT3 FSBS3 Systems FasNseal FSWT4 Tee: FSTT4 FSBS4 Inc.. 2SVSWTEF03 Tee: 2SVSTTF03 24SVSTPF03 Z-Flex...

  • Page 39: Concentric Polypropylene Venting

    iV. Venting D. Stainless Steel Venting (continued) Follow manufacturer’s instructions to Table 14: Concentric Vent Length attach terminal to vent system. inner/Outer Wall Vent Length (Equiv. Ft.) Boiler ii. Combustion Air Termination Pipe Dia., Opening Model Minimum * Maximum Diameter •...
  • Page 40 iV. Venting E. Concentric Polypropylene Venting (continued) Determine the required length of the outer d. Flue temperature sensor, factory attached to the pipe. When doing this allow an additional 1” boiler wiring harness, is secured to the left boiler of length for insertion into the female end of jacket panel with tape.
  • Page 41 iV. Venting E. Concentric Polypropylene Venting (continued) Figure 20: Fixed Extension (non-Cuttable) Figure 19: Cut-To-Length Extension (Cuttable) Figure 21: Cutting Straight Pipe iii. The male end of cuttable fittings must be held iv. Use locking bands (provided with all fittings) to the collar with three (3) #10 x 1/2”...
  • Page 42 iV. Venting E. Concentric Polypropylene Venting (continued) Horizontal Vent Termination a. Standard Concentric Termination Refer to Figure 24. Permitted terminals for horizontal venting: Horizontal (Wall) Terminal, [80/125 mm (P/N 101808-01), 100/150 mm (P/N 101809-01] - see Table 15. ii. Concentric Vent components supplied with the boiler are packed inside boiler carton and include the following: •...
  • Page 43 iV. Venting E. Concentric Polypropylene Venting (continued) Figure 26: Cutting Vent Terminal Pipe • Install the supplied Inside Wall Plate onto the CaUTiOn shortened Horizontal (Wall) Terminal interior end and move the plate to cover interior wall Exterior wall surface must be reasonably flat to cut opening.

  • Page 44: Removing The Existing Boiler

    iV. Venting E. Concentric Polypropylene Venting (continued) Vertical Vent Termination 3/8” into the outer pipe. Do not use a sheet metal screw longer than 1/2”. a. Standard Concentric Termination Refer to Figures 28 thru 32. • Secure the terminal section to the inside of the roof structure using the mounting bracket In addition to the vertical terminal, either a provided with the terminal (Figure 31).
  • Page 45 iV. Venting F. Removing the Existing Boiler (continued) Figure 28: Vertical Concentric Vent installation Figure 29: Dimension "H" Figure 30: Cutting Vertical Terminal Figure 31: Completing Vertical Terminal installation 103448-02 - 6/13...

  • Page 46: Multiple Boiler Installation Venting

    iV. Venting F. Removing the Existing Boiler (continued) 2. Inspecter de facon visuelle le système d’évcuation pour déterminer la grosseur et l’inclinaison horizontale qui conviennent et s’assurer que le système est exempt d’obstruction, d’étranglement, de fuite, de corrosion et autres défaillances qui pourraient présenter des risques.
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  • Page 48 iV. Venting G. Multiple Boiler Installation Venting (continued) However, if same sidewall placement is Warning problematic, an individual module (boiler) may be installed using vertical venting and sidewall no common manifolded venting (vent piping and combustion air intake termination (or, vice versa) vent terminals) is permitted.
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  • Page 50: Condensate Disposal

    iV. Venting G. Multiple Boiler Installation Venting (continued) h. When individual modules (boilers) are installed Sufficient inside space available at the base in the same horizontal plane, chimney chase of the chimney to install multiple chimney vertical concentric venting is permitted provided: chase brackets and support elbows.
  • Page 51 V. Condensate Disposal (continued) 2. A Condensate Neutralizer Kit (P/N 101867-01) nOTiCE is available as optional equipment. Follow local codes and instructions enclosed with the kit for Use materials approved by the authority having Condensate Neutralizer installation. jurisdiction. 3. Limestone chips will get coated by neutral salts (product of chemical reaction between limestone Condensate Neutralizer Installation and acidic condensate) and lose neutralizing...

  • Page 52: Water Piping And Trim

    Models Components a. Locate and remove ¾” NPT x close black nipple, Alpine (ALP) boilers have factory supplied Miscellaneous ¾” NPT black tee, ¾” MPT x ¾” FPT Pressure Part Carton (P/N 102942-01 – ALP080B thru ALP210B; Relief Valve, ¾” NPT Drain Valve.
  • Page 53 (1) ¾” NPT x 12” black nipple, ¾” NPT black tee, Piping System To Be Employed. ¾” FPT x ¾” FPT Pressure Relief Valve, ¾” NPT Alpine (ALP) boilers are designed to operate in a closed Drain Valve. loop pressurized system. Minimum pressure in the b.
  • Page 54 Vi. Water Piping and Trim B. Piping System To Be Employed (continued) and, a circulator selected to provide required 2. Direct connection of Alpine (ALP) boiler to flow at total calculated pressure drop. heating system, similar to a conventional boiler, is NOT RECOMMENDED because: c.
  • Page 55 Grundfos Circulator exceeds 50 equivalent feet, alternate circulator selection may be required. Table 17: recommended Circulator Models for alpine (aLP) Boilers Based on Listed Temperature Differential and 50 ft. Equivalent Length Near-Boiler Piping - Space Heating Circulator Boiler...
  • Page 56 The alpine (aLP) boiler heat exchanger is made from stainless steel tubular coil having relatively narrow waterways. Once filled with water, it will be subject to the effects of corrosion. Failure to take the following precautions to minimize corrosion and heat exchanger waterways overheating could result in severe boiler damage.
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  • Page 59 Observe the following guidelines when making the circulators will be required to properly install a actual installation of the boiler piping for special Alpine™ Series boiler. See Paragraph B above for situations: information on sizing the circulators. 1. Systems containing high level of dissolved oxygen 3.
  • Page 60 DHW circulators. required to achieve water heater rating, falls 2. For installations where indirect domestic hot water below the specified flow range for Alpine boiler heater is combined with space heating, when sizing model, the Alliance SL™ model must be piped...
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  • Page 67: Gas Piping

    Vii. gas Piping contact gas supplier for additional information. Warning Minimum gas valve inlet pressure is stamped on the rating label located in the boiler’s vestibule Failure to properly pipe gas supply to boiler compartment. may result in improper operation and damage 2.
  • Page 68 Vii. gas Piping (continued) Table 21B: 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 69 Vii. gas Piping (continued) Table 23: Specific Gravity Correction Factors 3. Alpine (ALP) boilers have factory supplied Specific Correction Specific Correction Miscellaneous Part Carton (P/N 101777-01 - gravity Factor gravity Factor ALP080B thru ALP210B; 101777-02 - ALP285B; 1012942-03 - ALP399), which includes gas piping 0.60...
  • Page 70 Vii. gas Piping (continued) Pressure test. See Table 24 for Alpine Min./Max. Gas Piping for Multiple Boiler Installation Pressure Ratings. The boiler and its gas connection 1. Individual module (boiler) gas pipe sizing specific must be leak tested before placing boiler in operation.

  • Page 71: Electrical

    Viii. Electrical DangEr 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 Failure to properly wire electrical connections to the boiler may result in serious physical harm. Electrical power may be from more than one source.
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  • Page 74 Viii. Electrical (continued) As with the sensor, the sensor wiring should be Refer to Figures 43 and 44 or details on the internal routed away from sources of electrical noise. Where boiler wiring. it is impossible to avoid such noise sources, wire Line Voltage (120 VAC) Connections - see Figure 43.
  • Page 75 Viii. Electrical (continued) Figure 44: Ladder Diagram 103448-02 - 6/13...
  • Page 76 Viii. Electrical (continued) Figure 45A: 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 103448-02 - 6/13...
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  • Page 81 Viii. Electrical (continued) Multiple Boiler Operating Information 1. Required Equipment and Setup a. Header Sensor (p/n 103104-01) A header sensor must be installed and wired to the Master Sequencer “enabled” Sage2.1 Controller. The header sensor is installed on the common system piping and provides blended temperature information to the Sequence Master.
  • Page 82 Viii. Electrical (continued) Figure 50: RJ45 Splitter Installation Detail d. Multiple Boiler Setup Step Description Comments Wire the header sensor to low voltage terminal strip terminals “Header sensor”. Install and wire the Header nOTE Sensor This step can not be skipped. The Sequence Master can not be “enabled”unless a Header Sensor is installed.

  • Page 83: System Start-Up

    IX. System Start-up 2. Alpine gas valves have inlet and outlet pressure Verify that the venting, water piping, gas piping and taps with built-in shut off screw. Turn each electrical system are installed properly. Verify that the screw from fully closed position three to four boiler condensate trap is filled with water.
  • Page 84 System Start-up (continued) Alpine™ Series Lighting and Operating Instructions Figure 51: Lighting instructions 103448-02 - 6/13...
  • Page 85 IX. System Start-up (continued) Check Burner Flame Status Control Action Inspect the flame visible through the window. On high Initiate Power-up fire the flame should be stable and mostly blue (Figure This state is entered when a delay is 52). No yellow tipping should be present; however, Standby Delay needed before allowing the burner control intermittent flecks of yellow and orange in the flame are...
  • Page 86 88% to 100% of the Each alpine Series boiler is tested at the factory value listed on the boiler rating label. and adjustments to the air fuel mixture are 10.
  • Page 87 180°F and, indirect water heater set point supply temperature is set to 170°F. If necessary, adjust these to Offset screw on each alpine Series boiler is the appropriate settings for the type of system to which adjusted at the factory to the specification. DO this boiler is connected.
  • Page 88 Boiler Model gas Valve Field Conversion From Natural Gas to LP Gas 0 - 7000 Ft. Alpine Series boilers are factory shipped as Natural Gas ALP080B 2¾ builds. Follow steps below for field conversion from Dungs Natural Gas to LP Gas.
  • Page 89 iX. System Start-up (continued) Warning The throttle adjustments shown in Table 28 are approximate. The final throttle setting must be found using a combustion analyzer. Leaving the boiler in operation with a CO level in excess of the value shown in Table 27 could result in injury or death from carbon monoxide poisoning.
  • Page 90 iX. System Start-up (continued) 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 91: Operation

    X. Operation (A. Overview) Overview 6. Warm Weather Shutdown (WWSD) Some boilers are used primarily for heating buildings, 1. Sage 2.1 Controller and the boilers can be automatically shutdown when The Sage 2.1 Controller (Control) contains features and the outdoor air temperature is warm. When outside air capabilities which help improve heating system operation, temperature is above the WWSD setpoint, this function efficiency and home comfort.

  • Page 92: Supply Water Temperature Regulation

    X. Operation B. Supply Water Temperature Regulation (continued) 4. Outdoor Air Reset Supply Water Temperature Regulation If an outdoor temperature sensor is connected to the boiler 1. Priority Demand and Outdoor Reset is enabled, the Central Heat setpoint The Control accepts a call for heat (demand) from will automatically adjust downwards as the outdoor multiple places and responds according to it’s “Priority”.

  • Page 93: Boiler Protection Features

    X. Operation C. Boiler Protection Features (continued) Boiler Protection Features 5. External Limit An external limit control can be installed between 1. Supply Water Temperature High Limit terminals 11 and 12 on the low voltage terminal strip. The boiler is equipped with independent automatic reset Be sure to remove the jumper when adding an external and a manual reset High Limit devices.

  • Page 94: Multiple Boiler Control Sequencer

    X. Operation D. Multiple Boiler Control Sequencer (continued) Multiple Boiler Control Sequencer is active, the sequence master uses DHW setpoint, “Diff Above”, “Diff Below” and pump settings. 1. “Plug & Play” Multiple Boiler Control Sequencer 7. Shared or Isolated DHW Demand When multiple boilers are installed, the Control’s Sequencer may be used to coordinate and optimize the When the Indirect Water Heater (IWH) parameter is set...

  • Page 95: Boiler Sequence Of Operation

    X. Operation E. Boiler Sequence Of Operation (continued) Boiler Sequence of Operation 1. Normal Operation Table 31: Boiler Sequence of Operation Status Screen Display Description Boiler 1 Priority: 140 F Supply (burner Off, circulator(s) Off) > Standby 140 F < Setpoint Boiler is not firing and there is no call for heat, priority equals standby.

  • Page 96: 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 97: Viewing Boiler Status

    X. Operation F. Viewing Boiler Status (continued) Viewing Boiler Status 1. 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 98: Detail Screens

    X. Operation F. Viewing Boiler Status (continued) 1. Status Screens (continued) Pump Status/Cycles Heat Demand Central Heat On System On < > < > Domestic Hot Water Off Boiler On Sequence Master Off DHW Off Frost Protection Off Frost Protection On Exercise On Pumping is a major part of any hydronic system.

  • Page 99: Multiple Boiler Sequencer Screens

    X. Operation F. Viewing Boiler Status (continued) 3. 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. Rate: Header: The rate % value is equal to the...

  • Page 100: Changing Adjustable Parameters

    X. Operation G. Changing Adjustable Parameters (continued) Adjust Changing Adjustable Parameters Active Fault 1. Entering Adjust Mode Warning! Only Qualified The Control is factory programmed Technicians Should Adjust to include basic modulating boiler Controls, Contact Your For Service Contact: functionality. These settings are password Qualified Heating Professional CONTRACTOR NAME protected to discourage unauthorized or...
  • Page 101 X. Operation G. Changing Adjustable Parameters (continued) 2. Adjusting Parameters (continued) 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 Modulation Setup...
  • Page 102 X. Operation G. Changing Adjustable Parameters (continued) 2. Adjusting Parameters (continued) Warning Boiler type is factory set and must match the boiler model. Only change the boiler type setting if you are installing a replacement Control. The boiler type setting determines minimum and maximum blower speeds. incorrect boiler type can cause hazardous burner conditions and improper operation that may result in PROPERTY LOSS, PHYSICAL INJURY OR LOSS OF LIFE.
  • Page 103 X. Operation G. Changing Adjustable Parameters (continued) Pump Setup “Press” 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. Any Demand: Pump Runs during any call for heat.
  • Page 104 X. Operation G. 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 105 X. Operation G. 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 106 X. Operation G. 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 107 X. Operation G. Changing Adjustable Parameters (continued) Central Heat “Press” button to access the following parameters: Factory range / Parameter and Description Setting Choices 80°F to Central Heat Setpoint 180°F 190°F Target temperature for the central heat priority. Value also used by the outdoor air reset function. Central Heat Thermostat “Sleep”...
  • Page 108 X. Operation G. Changing Adjustable Parameters (continued) Outdoor “Press” button to access the following parameters: Reset Factory range / Parameter and Description Setting Choices 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 57.
  • Page 109 X. Operation G. Changing Adjustable Parameters (continued) Central Heat Setpoint Boost Maximum Off Point Low Outside Air Temp = Central Heat Setpoint =180 F & 0 F minus Diff Above 10 F Default Boost Outdoor Air Reset Setpoint (Shown with thin lines, typical) TOD Setback Setpoint (Reset setpoint increased by 10 F every Default = 170 F...
  • Page 110 X. Operation G. Changing Adjustable Parameters (continued) Remote “Press” button to access the following parameters: 4-20mA 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 Local, demand directly without using the internal setpoint.

  • Page 111: Service And Maintenance

    Xi. Service and Maintenance DangEr 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. Do not attempt any service work if gas is present in the air in the vicinity of the boiler.
  • Page 112 2. System Freeze Protection: from debris. Inspect condensate line integrity between a. The following heating system freeze protection boiler and condensate neutralizer (if used), condensate products are recommended for Alpine boilers: neutralizer and the drain. Clean/repair if needed. 103448-02 - 6/13...
  • Page 113 Xi. Service and Maintenance (continued) Fernox™ Protector Alphi 11 (combined 1. Condensate Overflow Switch Removal and antifreeze and inhibitor). Replacement: Follow manufacturer application procedure a. Disconnect power supply to boiler. to insure proper antifreeze concentration and b. Remove two (2) wire nuts and disconnect overflow inhibitor level.
  • Page 114 Xi. Service and Maintenance (continued) e. Using pliers, release spring clip securing the k. Restore power supply to boiler. Fill up the trap overflow switch to condensate trap body and remove (see Section V “Condensate Disposal”) and verify the switch. Note that the switch has factory applied the switch operation.

  • Page 115: Troubleshooting

    Xii. Troubleshooting Warning Turn off power to boiler before working on wiring. 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 116 Xii. Troubleshooting (continued) Help Screen Faults indication Condition Possible Cause This alarm is active if the slave boiler has lost communication with the Sequence Master. Check the following: Sequencer Sequencer - RJ 45 peer-to-peer network disconnected Setup - Sequencer Master was Enabled and then Disabled Setup Fault - Master’s Boiler has been powered down.

  • Page 117: Lockout Condition

    Xii. Troubleshooting (continued) 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 118 Xii. Troubleshooting (continued) 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 119: 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 120 Xiii. repair Parts (continued) From Wiring Harness From Wiring Harness 103448-02 - 6/13...
  • Page 121 Xiii. repair Parts (continued) (Quantity) Part number Description aLP080B aLP105B aLP150B aLP210B aLP285B aLP399 Bare Heat Exchanger 101931-01 101931-02 101931-03 101931-04 101931-05 101931-06 Burner Head Assembly 101933-01 101933-02 101933-03 101933-04 101933-05 101933-06 Replacement Igniter Kit 103005-01 Replacement Flame Sensor Kit 103339-01 Replacement Partially Assembled Burner Door 102696-01...
  • Page 122 Xiii. repair Parts (continued) Part number Description aLP080B aLP105B aLP150B aLP210B aLP285B aLP399 Blower 101527-01 101528-01 101529-01 101530-01 Blower Inlet Shroud Assembly [includes Gas Orifice; Gas Orifice O-Ring; (3x) M4x20 mm or (3x) M4x25 mm self-threading screws; Injector Plate; (4x) M4 x 10 mm flat head screws; Air Intake Adapter - Air 101704-01 101704-02 101704-03...
  • Page 123 Xiii. repair Parts (continued) (Quantity) Part number Description aLP080B aLP105B aLP150B aLP210B aLP285B aLP399 Air Pressure Switch 104425-01 104426-01 Air Pressure Switch Tubing, Black 7016039 7016041 103473-01 Condensate Trap, Blow Molded 101239-01 Blocked Condensate Drain Switch 101587-01 Spring Clip, Condensate Trap (2) 101632-01 Rubber Grommet, Condensate Trap 101595-01...
  • Page 124 Xiii. repair Parts (continued) Part number Description Sage2.1 (Programmed) Kit 104472-01 104472-02 104472-03 Programmed Display 104427-01 (with Mounting Hardware) Sage2.1 Transformer 102516-01 103448-02 - 6/13...
  • Page 125 Xiii. repair Parts (continued) (Quantity) Part number Description aLP080B aLP105B aLP150B aLP210B aLP285B aLP399 Jacket, Rear/Bottom Panel 101217-01 101217-02 101217-03 101217-04 103406-01 103406-02 Jacket, Left Side Panel 102776-01 102776-02 102776-03 102776-04 102776-05 102776-06 Jacket, Right Side Panel 101216-01 101216-02 101216-03 101216-04 103406-01 103406-02...
  • Page 126 Xiii. repair Parts (continued) Quantity Vent System Components Part number aLP080B & aLP150B & aLP285B thru aLP105B aLP210B aLP399 3” Schedule 40 PVC Tee Vent/Combustion Air Terminal 102190-01 4” Schedule 40 PVC Tee Vent/Combustion Air Terminal 102190-02 3” Stainless Steel Rodent Screens 102191-01 4”...
  • Page 127 Xiii. repair Parts (continued) (Quantity) Part number Description aLP080B aLP105B aLP150B aLP210B aLP285B aLP399 MiSCELLanEOUS ParTS CarTOn 102942-01 102942-02 102942-03 Temperature/Pressure Gauge 100282-01 External Gas Shut Off Valve 806SOL0005 101615-01 Relief Valve 81660363 81660302 Boiler Drain Valve 806603061 Boiler Stacking Brackets (2) 101679-01 Boiler Stacking Bracket Screws (8) 80860743...
  • Page 128 Xiii. repair Parts (continued) (Quantity) Part number Description aLP080B aLP105B aLP150B aLP210B aLP285B aLP399 Vent Elbow w/Flue Sensor Port 102878-01 Rear Air Box 102867-01 Bottom Securing Bracket 102870-01 Hanging Bracket, Boiler 102868-01 Hanging Bracket, Wall 102869-01 Air Collar Plate Assembly 102871-02 102871-01 Air Collar Plate Gasket...
  • Page 129 Xiii. repair Parts (continued) Part number Description aLP080B aLP105B aLP150B aLP210B aLP285B aLP399 Complete Wiring Harness (includes 10A, 10B, 10C & 10D) 102701-02 Main (Low Voltage) Harness 103009-02 High Voltage Harness 103010-02 Blower Power Harness 103012-01 Communication Harness 103011-01 Igniter Harness 103486-01 Wiring Harness, Thermal Link &...
  • Page 130 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 about 1805°F, such as during direct flame contact, RCF changes into crystalline silica, a known carcinogen.

  • Page 131: Appendix A - Figures

    appendix a - Figures Figure Page Description number number Section I - Product Description, Specifications & Dimensional Data Figure 1A Models ALP080B thru ALP210B (Floor Mounted) Figure 1B Models ALP080B thru ALP210B (Wall Mounted) Figure 1C Models ALP285B thru ALP399 (Floor Mounted Only) Section iii - Pre-installation &...
  • Page 132 appendix a - Figures (continued) Figure Page Description number number Section iV - Venting (continued) Figure 30 Cutting Vertical Terminal Figure 31 Completing Vertical Terminal Installation Figure 32 Chimney Chase Installation Figure 33 Multiple Boiler Direct Vent Termination Figure 34 Multiple Boiler Concentric Vent Termination Section V - Condensate Disposal Figure 35...
  • Page 133 appendix a - Figures (continued) Figure Page Description number number Section X - Operation Figure 54 Status Screen Figure 55 Detail Screens Figure 56 Adjust Mode Screens Figure 57 Outdoor Reset Curve Section Xi - Service and Maintenance Figure 58 Igniter Electrode Gap Figure 59 Condensate Overflow Switch Orientation...

  • Page 134: Appendix B - Tables

    Fitting & Valve Equivalent Length Table 19 Multiple Boiler Water Manifold Sizing Recommended Circulator Models for Alpine (ALP) Boilers and Alliance SL Indirect Water Heaters Table 20 65 & 66 Installed as Part of Near-Boiler Piping Up to 75 Ft. Equivalent Length - Indirect Water Heater...
  • Page 135 appendix B - Tables (continued) Table Page Description number number Section Viii - Electrical Table 25 Boiler Current Draw Section iX - System Start-Up Table 26 Recommended Combustion Settings, Natural Gas Table 27 Recommended Combustion Settings, LP Gas Table 28 Number of Clockwise Throttle Screw Turns for LP Conversions Section X - Operation Table 29...
  • Page 136 U.S. Boiler Company, Inc. P.O. Box 3020 Lancaster, PA 17604 1-888-432-8887 www.usboiler.net 103448-02 - 6/13...

This manual is also suitable for:

Alp080bAlp105bAlp150bAlp210bAlp285bAlp399

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