IN S TAL L AT ION , OP E R AT IN G AN D S E R V IC E IN S T R U C T ION S F OR AL P I N E ™ C ON D E N S IN G H IGH E F F IC IE N C Y D IR E C T V E N T GA S - F I R E D H OT WAT E R BOI L E R 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).
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.
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.
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.
TABLE OF CONTENTS I. Product Description, Specifications and Dimensional Data...................... 6 II. Unpacking Boiler........................................................................................ 11 III. Pre-Installation and Boiler Mounting ........................................................ 12 IV. Venting...................................................................................................... 19 A. General Guidelines..............................................
I. Product Description, Specifications and Dimensional Data Alpine™ Series boilers are condensing high efficiency gas-fired direct vent hot water heating boilers designed for use in forced hot water space or space heating with indirect domestic hot water heating systems, where supply water temperature does not exceed 210°F.
103448-02 - 6/13 7 Figure 1A: Alpine™ - Models ALP080B thru ALP210B (Floor Mounted) I.
103448-02 - 6/13 Figure 1B: Alpine™ - Models ALP080B thru ALP210B (Wall Mounted) I.
103448-02 - 6/13 9 Figure 1C: Alpine™ - Models ALP285B thru ALP399 (Floor Mounted Only) I.
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 * Model Number ALP080B Input (MBH) Min. Max. Boiler Water Volume (Gal.) Heat Transfer Area (Sq. Ft.) 16 80 0.6 7.3 ALP105B 21 105 0.7 9.1 ALP150B 30 150 1.3 16.4 ALP210B 42 210 1.7 21.8 ALP285B 57 285 2.4 29.1 ALP399 80 399 3.4 41.
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 Model Number * Input (MBH) Min. Max. Boiler Water Volume (Gal.) Heat Transfer Area (Sq. Ft.) ALP150B 38 113 1.3 16.4 ALP210B 53 158 1.7 21.8 ALP285B 68 204 2.4 29.1 * Add Suffix “F” for Floor mounted Models or Suffix “W” for Wall mounted Models.
III. Pre-Installation and Boiler Mounting WARNING If you do not follow these instructions exactly, a fire or explosion may result causing property damage or personal injury. NOTICE Due to the low water content of the boiler, missizing of the boiler with regard to the heating system load will result in excessive boiler cycling and accelerated component failure. U.S. Boiler Company DOES NOT warrant failures caused by mis-sized boiler applications. DO NOT oversize the boiler to the system.
III. Pre-Installation and Boiler Mounting G. General (continued) c. Provide adequate space for condensate piping or a condensate pump if required. 6. Boiler Wall Hung Installation: a. If the boiler is installed on a framed wall, minimum acceptable framing is 2 x 4 studs on 16” centers. The boiler mounting holes are on 16” centers for installation between two studs at the standard spacing.
III. Pre-Installation and Boiler Mounting G.
III. Pre-Installation and Boiler Mounting G. General (continued) n. After the boiler has been piped, wired, connected to vent and combustion air system piping and combustion performance testing completed per Section IX “System Start-up”, install Access Panel/Gasket assembly and secure with provided four #8 x ½” black oxide Phillips head sheet metal screws. See Figure 2E “access Panel and Gasket Installation”. m.
III. Pre-Installation and Boiler Mounting G.
III. Pre-Installation and Boiler Mounting H. Boiler Stacking (continued) H. Boiler Stacking 1. For installations with unusually high space heating and/or domestic hot water heating loads, where employing two (2) Alpine (ALP) boilers will offer the benefits of greater operational efficiency, floor space savings and boiler redundancy, the Alpine (ALP) boilers may be installed stacked one on the top of the other. Refer to Table 3 “Alpine (ALP) Boiler Model Stacking Combinations” for details.
III. Pre-Installation and Boiler Mounting H. Boiler Stacking (continued) condensate disposal. Terminating individual boiler condensate lines into common pipe prior to drain disposal is permissible, providing common pipe has sufficient flow capacity to handle combined condensate volume of stackable combination. b. Gas Piping - Follow instructions in Section VII “Gas Piping” of the manual for sizing and installation of an individual boiler.
IV. Venting WARNING 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 interchange vent systems or materials unless otherwise specified. The use of thermal insulation covering vent pipe and fittings is prohibited. Do not use a barometric damper, draft hood or vent damper with this boiler.
IV. Venting A.
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. Maintain the correct clearance and orientation between the vent and air intake terminals. i. The centerlines between the vent and air intake terminals must be spaced a minimum of 12” apart.
IV. Venting A. General Guidelines (continued) B. CPVC/PVC Venting n. If possible, install the vent and air intake terminals on a wall away from the prevailing wind. Reliable operation of this boiler cannot be guaranteed if the terminal is subjected to winds in excess of 40 mph. o. Air intake terminal must not terminate in areas that might contain combustion air contaminates, such as near swimming pools. p.
IV. Venting B. CPVC/PVC Venting (continued) d. Follow all manufacturer instructions and warnings when preparing pipe ends for joining and using the primer and the cement. b. Align vent connector plate and gasket clearance holes with rear/bottom panel engagement holes; than, secure the connector and gasket to the panel with six mounting screws. c.
IV. Venting B. CPVC/PVC Venting (continued) Table 5C: CPVC/PVC Vent & Air Intake Components (Installer Provided) required for Optional Vertical (Roof) Termination Vent Components Part Number 3" Schedule 40 PVC Coupler 4" Schedule 40 PVC Coupler N/A 3" Schedule 40 PVC 90° Elbow Supplied 4" Schedule 40 PVC 90° Elbow by Others 3" Schedule 40 CPVC Pipe x ½ ft. min. horizontal run 4" Schedule 40 CPVC Pipe x ½ ft. min.
IV. Venting B. CPVC/PVC Venting (continued) L 4 CHANGE OF DIRECTION (VERTICAL OR HORIZONTAL) OFFSET LONG RUN OF PIPE L L 2 LOOP LENGTH (L) KEY RESTRAINT (RESTRICTS MOVEMENT) L 4 HANGER (ALLOWS MOVEMENT) Table 7: Expansion Loop Lengths Nominal Pipe Dia. (In.) 3 Length of Straight Run (Ft.) 20 30 40 50 60 4 20 30 40 50 60 LOOP (HORIZONTAL ONLY) (TOP VIEW) Loop Length “L” (In.
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) Combustion Air Pipe (Equivalent Length) Boiler Model Min. Max. ALP080B 30 In. ALP105B 30 In. 4” (100 mm) Combustion Air Pipe (Equivalent Length) Min. 3” (80 mm) Vent Pipe (Equivalent Length) Max. Min. Max. 135 Ft. 30 In. 135 Ft. 135 Ft. 30 In. 135 Ft.
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. iii. Clean all vent and combustion air pipe joints with primer and secure with transition cement (4-oz. bottles of primer and cement are supplied with boiler).
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. NOTICE Exterior run to be included in equivalent vent/ combustion air lengths.
IV. Venting B. CPVC/PVC Venting (continued) 7. Vertical Vent Termination a. Standard Two-Pipe Termination Refer to Figures 8, 10, 12 and 13. i. 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. • Whenever possible, install vent straight through the roof. Refer to Figures 12 and 13. - Size roof opening to maintain minimum clearance of 1" from combustible materials.
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. ii. Combustion Air Piping • Locate combustion air termination on the same roof location as the vent termination to prevent nuisance boiler shutdowns. Combustion air terminal can be installed closer to roof than vent.
IV. Venting C. Polypropylene Venting (continued) M&G/DuraVent PolyPro Single Wall Rigid Vent and PolyPro Flex Flexible Vent comply with the requirements of ULC-S636-08 ‘Standard for Type BH Gas Venting Systems’. Centrotherm Eco Systems InnoFlue SW Rigid Vent and Flex Flexible Vent comply with the requirements of UL 1738 ‘Standard for Safety for Venting Systems’ and ULC-S636-08 ‘Standard for Type BH Gas Venting Systems’.
IV. Venting C. Polypropylene Venting (continued) CAUTION Bending or attempting to install flexible pipe if it has been stored at ambient temperature below 41°F (5°C) will cause material to become brittle and lead to cracks. • When flexible polypropylene pipe (liner) is used for combustion product venting, it must not be installed at an angle greater than 45 degrees from vertical plane. This will insure proper condensate flow back towards the boiler.
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. See Figure 5 for details.
IV. Venting C. Polypropylene Venting (continued) 11) Apply provided dielectric grease (grease pouch taped to the vent system connector) all around to the vent or air connection inner red silicon gasket. 12) Push and twist PVC to PP boiler adapter (ISAA0303 or ISAA0404 as applicable) into two-pipe vent system connector vent connection or air supply port until bottomed out. 13) Tighten the worm band clamp screw to secure PVC to PP boiler adapter.
IV. Venting C. Polypropylene Venting (continued) 19) Lubricate PVC to PP adapter outer seal with water (or approved water based lubricant), than, insert and push lubricated adapter end into CPVC coupling open end until bottomed out. 20) If using polypropylene pipe for combustion air intake, repeat the above step installing the adapter into PVC air intake.
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.
IV. Venting D. Stainless Steel Venting (continued) D. 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 undamaged in the female end of the pipe. • Make sure that both the male and female pipes are free of damage prior to assembly. • Only cut vent pipe as permitted by the vent manufacturer in accordance with their instructions.
IV. Venting D. Stainless Steel Venting (continued) Table 13B: Alternate Vent Systems and Vent Components (Stainless Steel) Manufacturer Vent System Protech Systems Inc..
IV. Venting D. Stainless Steel Venting (continued) Follow manufacturer’s instructions to attach terminal to vent system. ii. Combustion Air Termination • Install vertical combustion air terminal. Vertical combustion air terminal consists of an 180° bend (comprised of two (2) 90° elbows) as shown in Figure 12. • Install rodent screen (not supplied) in the combustion air terminal. Use a screen having 1/2” (2 x 2) or larger mesh. E.
IV. Venting E. Concentric Polypropylene Venting (continued) d. Flue temperature sensor, factory attached to the boiler wiring harness, is secured to the left boiler jacket panel with tape. e. Remove the tape and push the sensor rubber plug into Concentric Vent Collar sensor port until the plug is securely engaged. See Figure 18. The installation of the Concentric Vent Collar is now completed. 3. i. ii. iii. System Assembly a.
IV. Venting E. Concentric Polypropylene Venting (continued) Figure 19: Cut-To-Length Extension (Cuttable) Figure 20: Fixed Extension (Non-Cuttable) Figure 21: Cutting Straight Pipe iii. The male end of cuttable fittings must be held to the collar with three (3) #10 x 1/2” sheet metal screws. Drill a 1/8 hole through both outer pipes to start this screw. Use a drill stop or other means to ensure that the drill bit does not penetrate more than 3/8” into the outer pipe.
IV. Venting E. Concentric Polypropylene Venting (continued) 4. Horizontal Vent Termination a. Standard Concentric Termination Refer to Figure 24. i. 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.
IV. Venting E. Concentric Polypropylene Venting (continued) Figure 26: Cutting Vent Terminal Pipe CAUTION Exterior wall surface must be reasonably flat to attach the Outside Wall Plate. When exterior wall surface is not flat (covered with vinyl or wood shingle siding etc.) the siding must be removed, and a flat surface build up flash or above siding exterior surface to secure/seal the terminal Outside Wall Plate.
IV. Venting E. Concentric Polypropylene Venting (continued) 5. Vertical Vent Termination a. Standard Concentric Termination Refer to Figures 28 thru 32. i. In addition to the vertical terminal, either a Flat Roof Flashing or Sloped Roof Flashing is required for this installation. Refer to Table 15 ‘Concentric Vent Components’ for details. • Determine the centerline of the terminal location on the roof.
IV. Venting F.
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. 3.
103448-02 - 6/13 47 Figure 33: Multiple Boiler Direct Vent Termination IV. Venting G.
IV. Venting G. Multiple Boiler Installation Venting (continued) WARNING No common manifolded venting (vent piping and vent terminals) is permitted. c. The individual module (boiler) maximum vent length - see Section IV, “Venting”, Table 8. d. For sidewall venting the minimum horizontal distance between any adjacent individual module (boiler) vent terminations is twelve (12) inches.
103448-02 - 6/13 49 Figure 34: Multiple Boiler Concentric Vent Termination IV. Venting G.
IV. Venting G. Multiple Boiler Installation Venting (continued) h. When individual modules (boilers) are installed in the same horizontal plane, chimney chase vertical concentric venting is permitted provided: i. Sufficient inside space available at the base of the chimney to install multiple chimney chase brackets and support elbows. ii. Spacing between adjacent vertical vent terminals is in accordance with Item ‘g’ above. V. Condensate Disposal A. Condensate Trap and Drain Line. 1.
V. Condensate Disposal (continued) NOTICE Use materials approved by the authority having jurisdiction. B. Condensate Neutralizer Installation 1. Some jurisdictions may require that the condensate be neutralized before being disposed of. Follow local codes pertaining to condensate disposal. 2. A Condensate Neutralizer Kit (P/N 101867-01) is available as optional equipment. Follow local codes and instructions enclosed with the kit for Condensate Neutralizer installation. 3.
VI. Water Piping and Trim WARNING Failure to properly pipe boiler may result in improper operation and damage to boiler or structure. Install boiler so that the gas ignition system components are protected from water (dripping, spraying, rain, etc.) during boiler operation and service (circulator replacement, etc.). Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components, and can lead to boiler failure. U.S.
VI. Water Piping and Trim A. Factory Supplied Piping and Trim (continued) 2. Relief Valve Piping, ALP285B and ALP399 Boiler Models a. Locate and remove (1) ¾” NPT x close black nipple, (1) ¾” NPT x 12” black nipple, ¾” NPT black tee, ¾” FPT x ¾” FPT Pressure Relief Valve, ¾” NPT Drain Valve. b. Install close nipple into tee branch, then, screw the assembly into boiler left side front ¾” tapping making sure tee run outlets are in vertical plane and parallel to boiler side. c.
VI. Water Piping and Trim B. Piping System To Be Employed (continued) and, a circulator selected to provide required flow at total calculated pressure drop. c. It is often very difficult to accurately calculate the pressure drop through the system. d. In replacement installations, it may be nearly impossible to get an accurate measurement of piping amount and number of fittings in the system.
VI. Water Piping and Trim B. Piping System To Be Employed (continued) 3. Alpine boiler models ALP080B thru ALP285B are factory supplied with circulators, which were sized for near-boiler piping equivalent length of 50 ft. and listed temperature differential. See Table 17 for details. It is the installer’s responsibility to insure a proper installation and where applicable, proper circulator speed setting for the boiler circulator to achieve a required flow rate.
VI. Water Piping and Trim C. Standard Installation Requirements (continued) Table 18: Fitting and Valve Equivalent Length Table 18: Fitting and Valve Equivalent Length (cont’d) Copper Fitting and Sweat Valve Equivalent Length (Ft) Fitting or Valve Description Copper Pipe or Valve Size 1 1¼ 1½ 2 90° Elbow 2.5 3.0 4.0 5.5 45° Elbow 1.0 1.2 1.5 2.0 Tee (thru flow) 0.5 0.6 0.8 1.0 Tee (Branch flow) 4.5 5.5 7.0 9.0 Diverter Tee (typical) 23.5 25.0 23.0 23.0 Gate Valve 0.3 0.
103448-02 - 6/13 57 CAUTION It is the installers responsibility to select pumps and boiler piping configurations that provide the proper flow rates and performance for the boiler and indirect water heater. Refer to Table 17 for recommended Boiler Loop Circulator. Figure 37: Near Boiler Piping - Heating Only VI. Water Piping and Trim C.
103448-02 - 6/13 CAUTION It is the installers responsibility to select pumps and boiler piping configurations that provide the proper flow rates and performance for the boiler and indirect water heater. Refer to Table 17 for recommended Boiler Loop Circulator. Figure 38: Near Boiler Piping - Heating Plus Indirect Water Heater VI. Water Piping and Trim C.
VI. Water Piping and Trim C. Standard Installation Requirements (continued) of the discharge pipe must terminate in an unthreaded pipe. If the relief valve is not piped to a drain, it must terminate at least 6” above the floor. Do not run relief valve discharge piping through an area prone to freezing. The termination of discharge piping must be in an area where it will not become plugged by debris.
VI. Water Piping and Trim E. Multiple Boiler Installation Water Piping (continued) Figure 39: Isolation of the Boiler From Oxygenated Water with A Plate Heat Exchanger 3. Boiler Piping with Air Handlers - Where the boiler is connected to air handlers through which refrigerated air passes, use flow control valves in the boiler piping or other automatic means to prevent gravity circulation during the cooling cycle. E. Multiple Boiler Installation Water Piping – (See Table 19 and Figures 40B and 41B) 1.
103448-02 - 6/13 61 Figure 40A: Multiple Boiler Water Piping w/Domestic Hot Water Heater (Page 1 of 2) Installing a low water cutoff in the system piping of multiple boilers is strongly recommended and may be required by Local Codes. NOTICE VI. Water Piping and Trim E.
103448-02 - 6/13 Figure 40B: Multiple Boiler Water Piping w/Domestic Hot Water Heater (Page 2 of 2) Installing a low water cutoff in the system piping of multiple boilers is strongly recommended and may be required by Local Codes. NOTICE VI. Water Piping and Trim E.
103448-02 - 6/13 63 Figure 41A: Alternate Multiple Boiler Water Piping w/ Indirect Domestic Hot Water Heater (Page 1 of 2) It is the installers responsibility to select pumps and boiler piping configurations that provide the proper flow rates and performance for the boiler and indirect water heater. Refer to Table 17 for recommended Boiler Loop Circulator. CAUTION VI. Water Piping and Trim E.
103448-02 - 6/13 It is the installers responsibility to select pumps and boiler piping configurations that provide the proper flow rates and performance for the boiler and indirect water heater. Refer to Table 20 for recommended Boiler Loop Circulator. CAUTION Figure 41B: Alternate Multiple Boiler Water Piping w/Indirect Domestic Hot Water Heater (Page 2 of 2) VI. Water Piping and Trim E.
103448-02 - 6/13 65 1 ALP150B 1 1 1 1 1 1 1 1 1 13.8 9.6 7.3 11 7.7 5.8 Flow, GPM @ 25°F DT 14 SL119 7.9 5.5 17 9 9 9.5 10 17 9 9 9.5 10 17 9 9 9.5 10 6 6 6 6 14 6 6 6 6 14 6 6 6 6 SL27 SL35 SL50 SL70 SL119 SL27 SL35 SL50 SL70 SL119 SL27 SL35 SL50 SL70 4.2 Alliance SL Coil Head Loss, Ft @ Required Flow Rate Min Req’d Alliance SL Alliance Flow thru Models to SL Boiler, be installed Coil GPM As Part of Required @ 35°F Near-Boiler Flow Rate, DT Piping GPM 36 NA 19.3 19.3 19.
103448-02 - 6/13 1-1/2 ALP399 1-1/2 1-1/4 1 2 1-1/2 1-1/4 2 1-1/2 1-1/4 37.7 26.5 19.4 30.2 21.2 15.5 Flow, GPM @ 25°F DT 21.5 15.1 11.1 6 6 6 6 14 6 6 6 6 14 6 6 6 6 14 SL119 SL27 SL35 SL50 SL70 SL119 SL27 SL35 SL50 SL70 SL119 Alliance SL Coil Required Flow Rate, GPM SL27 SL35 SL50 SL70 Min Req’d Alliance SL Flow thru Models to Boiler, be installed GPM As Part of @ 35°F Near-Boiler DT Piping 9 9 9.5 10 17.0 17.0 9 9 9.5 10 17 9 9 9.
VII. Gas Piping contact gas supplier for additional information. Minimum gas valve inlet pressure is stamped on the rating label located in the boiler’s vestibule compartment. WARNING Failure to properly pipe gas supply to boiler may result in improper operation and damage to the boiler or structure. Always assure gas piping is absolutely leak free and of the proper size and type for the connected load. An additional gas pressure regulator may be needed. Consult gas supplier. 2. Maximum gas demand.
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 Pipe Size, In. Diameter, In. Length of Pipe, Ft. 10 20 30 40 50 60 70 80 90 100 ½ 0.622 88 60 48 41 37 33 31 29 27 25 ¾ 0.824 184 126 101 87 77 70 64 60 56 53 1 1.049 346 238 191 163 145 131 121 112 105 100 1¼ 1.
VII. Gas Piping (continued) Table 23: Specific Gravity Correction Factors Specific Gravity Correction Factor Specific Gravity Correction Factor 0.60 1.00 0.90 0.82 0.65 0.96 1.00 0.78 0.70 0.93 1.10 0.74 0.75 0.90 1.20 0.71 0.80 0.87 1.30 0.68 0.85 0.81 1.40 0.66 B. Connect boiler gas valve to gas supply system. CAUTION The gas valve and blower will not support the weight of the piping. Do not attempt to support the weight of the piping with the boiler gas valve.
VII. Gas Piping (continued) C. Pressure test. See Table 24 for Alpine Min./Max. Pressure Ratings. The boiler and its gas connection must be leak tested before placing boiler in operation. 1. Protect boiler gas control valve. For all testing over ½ psig, boiler and its individual shutoff valve must be disconnected from gas supply piping. For testing at ½ psig or less, isolate boiler from gas supply piping by closing boiler’s individual manual shutoff valve. 2.
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. Make sure all power is off before attempting any electrical work.
103448-02 - 6/13 VIII.
103448-02 - 6/13 73 VIII.
VIII. Electrical (continued) C. Refer to Figures 43 and 44 or details on the internal boiler wiring. Line Voltage (120 VAC) Connections - see Figure 43. 1. The line voltage connections are located in the junction box on the left side of the vestibule. The terminal block TB-1 in conjunction with terminal screw identification label is attached to the junction box combination cover/inside high voltage bracket. 2. The conductor insulation colors are: a. Black – L1 line voltage “Hot” b.
VIII.
VIII.
103448-02 - 6/13 77 4 3 2 1 5 4 3 2 1 5 4 3 2 1 5 FLAIR "VJ" ZONE VALVES (SEE NOTE) 2 RD YE 1 3 1 3 2 RD YE 4 2 RD YE 4 3 2 1 2 3 2 1 RD YE 2 RD YE 1 3 4 2 3 2 YE WHITE ROGERS #1361-102 ZONE VALVES 2 WIRE (24V) THERMOSTATS W/ HEAT ANTICIPATOR SET AT 0.3 AMPS (40VA REQ'D FOR EVERY 4 ZONE VALVES) HONEYWELL V8043E ZONE VALVES 2 WIRE (24V) THERMOSTATS W/ HEAT ANTICIPATOR SET AT 0.
103448-02 - 6/13 VIII. Electrical (continued) Figure 46: Multiple Boiler Wiring Diagram Internal Sage2.
103448-02 - 6/13 79 Tekmar 265 Based Control System (or equal) Sequence of Operation Figure 47A: Multiple Boiler Wiring Diagram w/Tekmar 265 Control The Tekmar 265 Control (or equal) can control up to three (3) boilers and an Indirect Water Heater. When a call for heat is received by the Tekmar 265 Control, the control will fire either one or more boilers in either parallel or sequential firing mode to establish a required reset water temperature in the system supply main based on outdoor temperature.
103448-02 - 6/13 Tekmar 264 Based Control System (or equal) Sequence of Operation Figure 47B: Multiple Boiler Wiring Diagram w/Tekmar 264 Control The Tekmar 264 Control (or equal) can control up to four (4) boilers and an Indirect Water Heater by utilizing stage firing.
VIII. Electrical (continued) G. 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. Refer to piping diagram Figures 40A and 41A for installation location and Figure 48 or 49 for installation detail. b.
VIII. Electrical (continued) Figure 50: RJ45 Splitter Installation Detail d.
IX. System Start-up A. Verify that the venting, water piping, gas piping and electrical system are installed properly. Verify that the boiler condensate trap is filled with water. Refer to installation instructions contained in this manual. B. Confirm all electrical, water and gas supplies are turned off at the source and that vent is clear of obstructions. C. Confirm that all manual shut-off gas valves between the boiler and gas source are closed.
IX.
IX. System Start-up (continued) Status Control Action Initiate Power-up This state is entered when a delay is Standby Delay needed before allowing the burner control to be available and for sensor errors. Standby Boiler is not firing. There is no call for heat or there is a call for heat and the temperature is greater than setpoint. Safe Startup Tests flame circuit then checks for flame signal. Drive Purge Driving blower to purge rate setting and waiting for the proper fan feedback.
IX. System Start-up (continued) 5. Obtain gas-heating value (Btu per cubic foot) from gas supplier. 6. Multiply hourly gas flow rate by gas heating value to determine the boiler input rate, BTU/hr Example: Natural gas heating value provided by local gas utility is 1050 Btu per cubic foot. Measured and calculated hourly gas flow rate is 100 cu ft/hr. Measured boiler input rate is: 100 cu ft/hr x 1050 BTU/ cu ft = 105, 000 BTU/hr 7. Compare measured input rate to input rate value stated on rating label.
IX. System Start-up (continued) Table 27: Typical Combustion Values, LP Gas % CO2 Altitude Range 0 - 7000 Ft. % O2 Range 11.4 - 9.5 (High Fire) 3.5 - 6.5 (High Fire) 11.4 - 9.1 (Low Fire) 3.5 - 7.0 (Low Fire) Boiler Model ALP080B ALP105B ALP150B ALP210B ALP285B ALP399 CO, PPM 7. If the boiler is converted from natural to LP gas then use a label sheet which is provided with the boiler for conversions from natural to LP gas. Otherwise skip this Step and proceed to Step 8.
IX. System Start-up (continued) Q. Adjust Thermostats Adjust the heating and indirect water heater thermostats to their final set points. R. Field Conversion From Natural Gas to LP Gas Alpine Series boilers are factory shipped as Natural Gas builds. Follow steps below for field conversion from Natural Gas to LP Gas.
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. NOTICE If the throttle is very far out of adjustment on the “rich” (counter-clockwise) side, the boiler burner may be running at 0% Excess Air or even with air deficiency.
IX. System Start-up (continued) S. 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. No. 1 Title Check Wiring Terminal Description 1&2 Is the heating thermostat connected? Insure this is “dry”, non-powered input.
X. Operation (A. Overview) A. Overview 1. Sage 2.1 Controller The Sage 2.1 Controller (Control) contains features and capabilities which help improve heating system operation, efficiency and home comfort. By including unique capabilities, the Control can do more, with less field wiring, and fewer aftermarket controls and components – improving the operation of both new and replacement boiler installations. 2.
X. Operation B. Supply Water Temperature Regulation (continued) B. Supply Water Temperature Regulation 1. Priority Demand The Control accepts a call for heat (demand) from multiple places and responds according to it’s “Priority”. When more than 1 demand is present the higher priority demand is used to determine active boiler settings. For example, when Domestic Hot Water (DHW) has priority the setpoint, “Diff Above”, “Diff Below” and pump settings are taken from DHW selections.
X. Operation C. Boiler Protection Features (continued) C. Boiler Protection Features 1. Supply Water Temperature High Limit The boiler is equipped with independent automatic reset and a manual reset High Limit devices. The automatic reset high limit is provided by a supply manifold mounted Limit Device. The automatic high limit is set to 200°F. The Control monitors a supply water temperature sensor that is also mounted in the supply water manifold and supplies an internal, manual reset high limit.
X. Operation D. Multiple Boiler Control Sequencer (continued) D. Multiple Boiler Control Sequencer 1. “Plug & Play” Multiple Boiler Control Sequencer When multiple boilers are installed, the Control’s Sequencer may be used to coordinate and optimize the operation of up to eight (8) boilers. Boilers are connected into a “network” by simply “plugging in” standard ethernet cables into each boiler’s “Boiler-To-Boiler Communication” RJ45 connection. 2.
X. Operation E. Boiler Sequence Of Operation (continued) E. Boiler Sequence of Operation 1.
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” after 4 minutes. The “Home Screen” displays boiler temperature, boiler status and Efficiency Information.
X. Operation F. Viewing Boiler Status (continued) F. 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” button from the “Home” screen.
X. Operation F. Viewing Boiler Status (continued) 1. Status Screens (continued) i i Pump Status/Cycles < System On Boiler On DHW Off Frost Protection On 98 23 0 > < Heat Demand Central Heat On Domestic Hot Water Off Sequence Master Off Frost Protection Off > Exercise On 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.
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. Header: measured header water temperature. This is the temperature being used to start, stop and fire boiler when there is a call-for-heat. Setpoint: this is the active setpoint.
X. Operation G. Changing Adjustable Parameters (continued) Adjust G. Changing Adjustable Parameters Active Fault Warning! Only Qualified Technicians Should Adjust Controls, Contact Your Qualified Heating Professional 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.
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 Setup Pump Setup Manual Control The following pages describe the Control’s adjustable parameters.
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.
X. Operation G. Changing Adjustable Parameters (continued) “Press” Pump Setup Factory Setting Central Heat, Optional Priority Any Demand Primary Loop Pipe IWH button to access the following parameters: Range / Choices Never, Any Demand, Central heat, No Priority, Central Heat, Optional Priority Any Demand, Central heat, off DHW demand Never, Primary Loop Piped IWH, Boiler Piped IWH Parameter and Description System Pump run pump for: Activates the system pump output according to selected function.
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 system pump to run or not run when there is a domestic hot water call for heat.
X. Operation G.
X. Operation G. Changing Adjustable Parameters (continued) “Press” Contractor Setup button to access the following parameters: i Contractor name For Service Contact: Bill Smith 12 Victory Lane Plainview, New York 516 123-4567 Press box to input contractor information. < > Bill Smith Save Press SAVE button to store revisions.
X. Operation G. Changing Adjustable Parameters (continued) “Press” Central Heat button to access the following parameters: Factory Setting Range / Choices 180°F 80°F to 190°F Central Heat Setpoint Target temperature for the central heat priority. Value also used by the outdoor air reset function.
X. Operation G. Changing Adjustable Parameters (continued) “Press” Outdoor Reset Factory Setting Enabled button to access the following parameters: Range / Choices Enable Disable Parameter and Description 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.
X. Operation G. Changing Adjustable Parameters (continued) Central Heat Setpoint Low Outside Air Temp =180 F & 0 F 200 195 Boost Maximum Off Point = Central Heat Setpoint minus Diff Above 190 185 180 175 170 160 155 150 145 140 135 10 F Hot Water Setpoint 165 130 Default Boost Outdoor Air Reset Setpoint (Shown with thin lines, typical) (Reset setpoint increased by 10 F every 20 minutes that demand is not satisfied.
X. Operation G. Changing Adjustable Parameters (continued) “Press” Factory Setting Remote 4-20mA button to access the following parameters: Range / Choices Parameter and Description 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. The 4-20mA selection is used to enable a remote multiple boiler Local 4-20mA controller to control the Sage2.
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. Never modify, remove or tamper with any control device.
XI. Service and Maintenance (continued) CAUTION Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing. 4. Remove the igniter assembly and flame sensor and inspect them for oxide deposits. Clean the oxide deposits from the igniter electrodes and flame sensor rod with steel wool. Do not use sandpaper for the cleaning.
XI. Service and Maintenance (continued) i. Fernox™ Protector Alphi 11 (combined antifreeze and inhibitor). Follow manufacturer application procedure to insure proper antifreeze concentration and inhibitor level. Above referenced product is available from Cookson Electronics Company, 4100 Sixth Avenue, Altoona, PA 16602, Tel: (814) 9461611 and/or selected HVAC distributors. Contact U.S. Boiler Company for specific details. b.
XI. Service and Maintenance (continued) e. Using pliers, release spring clip securing the overflow switch to condensate trap body and remove the switch. Note that the switch has factory applied silicon adhesive seal, which may have to be carefully cut all around to facilitate the switch removal. f. Using pliers, release spring clip securing condensate trap body to the heat exchanger bottom drain stab. g.
XII. Troubleshooting WARNING 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 “Priority” show “Standby”. Boiler not responding to a call for heat, “Status” shows “Standby” and “Priority” shows Central Heat or Domestic Hot Water. Boiler is not seeing call for heat.
XII. Troubleshooting (continued) C. Help Screen Faults Indication Condition Sequencer Setup Fault Sequencer Setup Flashing Boiler Size Fault Boiler Size Setup Flashing Possible Cause This alarm is active if the slave boiler has lost communication with the Sequence Master. Check the following: - RJ 45 peer-to-peer network disconnected - Sequencer Master was Enabled and then Disabled - Master’s Boiler has been powered down.
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. The boiler will automatically restart once the condition that caused the lockout is corrected.
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. Once the condition that caused the lockout is corrected, the boiler will need to be manually reset using the Reset button on the “Active Fault” display or located on the Sage2.1 Control.
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.
XIII.
XIII. Repair Parts (continued) 1R 1V 1T 1Q 1U 1S Key Description No.
XIII. Repair Parts (continued) Key No.
XIII. Repair Parts (continued) Key No. 4A 4B 4C 4D 4E 4F 4G Description Air Pressure Switch Air Pressure Switch Tubing, Black Condensate Trap, Blow Molded Blocked Condensate Drain Switch Spring Clip, Condensate Trap Rubber Grommet, Condensate Trap Condensate Comp.
XIII. Repair Parts (continued) Key No. 5A 5B 5C 124 Description Sage2.1 (Programmed) Kit Programmed Display (with Mounting Hardware) Sage2.
XIII. Repair Parts (continued) Key No.
XIII. Repair Parts (continued) Key No.
XIII. Repair Parts (continued) Key No.
XIII. Repair Parts (continued) Key No.
XIII. Repair Parts (continued) Key No.
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. When disturbed as a result of servicing or repair, these substances become airborne and, if inhaled, may be hazardous to your health.
Appendix A - Figures Figure Number Page Number Description Section I - Product Description, Specifications & Dimensional Data Figure 1A 7 Models ALP080B thru ALP210B (Floor Mounted) Figure 1B 8 Models ALP080B thru ALP210B (Wall Mounted) Figure 1C 9 Models ALP285B thru ALP399 (Floor Mounted Only) Section III - Pre-Installation & Boiler Mounting Figure 2A 14 Clearances To Combustible and Non-combustible Material, Floor Standing Figure 2B 14 Clearances To Combustible and Non-combustible Materi
Appendix A - Figures (continued) Figure Number Page Number Description Section IV - Venting (continued) Figure 30 45 Cutting Vertical Terminal Figure 31 45 Completing Vertical Terminal Installation Figure 32 46 Chimney Chase Installation Figure 33 47 Multiple Boiler Direct Vent Termination Figure 34 49 Multiple Boiler Concentric Vent Termination Section V - Condensate Disposal Figure 35 51 Condensate Trap and Drain Line Section VI - Water Piping and Trim Figure 36 52 Factory Supplied
Appendix A - Figures (continued) Figure Number Page Number Description Section X - Operation Figure 54 97 Status Screen Figure 55 98 Detail Screens Figure 56 100 Adjust Mode Screens Figure 57 109 Outdoor Reset Curve Section XI - Service and Maintenance Figure 58 112 Igniter Electrode Gap Figure 59 113 Condensate Overflow Switch Orientation Section XII - Troubleshooting Figure 60 115 Help Menu Section XIII - Repair Parts N/A Pages 120 thru 129 103448-02 - 6/13 133
Appendix B - Tables Table Number Page Number Description Section I - Product Description, Specifications & Dimensional Data Table 1 6 Dimensional Data (See Figures 1A, 1B, & 1C) Table 2A 10 Rating Data - Models ALP080B thru ALP399 (0 to 2000 Feet Elevation Above Sea Level) Table 2B 10 Rating Data - Models ALP080B thru ALP399 (2001 to 7000 Feet Elevation Above Sea Level) Table 2C 11 Rating Data - Models ALP150B thru ALP285B (7001 to 10,000 Feet Elevation Above Sea Level) Section III - Pre-Inst
Appendix B - Tables (continued) Table Number Page Number Description Section VIII - Electrical Table 25 74 Boiler Current Draw Section IX - System Start-Up Table 26 86 Recommended Combustion Settings, Natural Gas Table 27 87 Recommended Combustion Settings, LP Gas Table 28 88 Number of Clockwise Throttle Screw Turns for LP Conversions Section X - Operation Table 29 92 Priority Table 30 93 Frost Protection Table 31 95 Boiler Sequence of Operation Table 32 102 Parameters Changed Usin
U.S. Boiler Company, Inc. P.O. Box 3020 Lancaster, PA 17604 1-888-432-8887 www.usboiler.
