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, Burnham by 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. II. III. IV. V. VI. VII. VIII. IX. X. XI. XII. XIII. XIV. XV. Product Description, Specifications and Dimensional Data...................... 6 Pre-Installation & Boiler Mounting ............................................................ 13 Unpacking Boiler........................................................................................ 17 Venting...................................................................................................... 18 A. General Guidelines...
I. Product Description, Specifications and Dimensional Data Alpine™ Series boilers are condensing high efficiency gas-fired direct vent hot water 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.
Figure 1A: Alpine™ - Models ALP080 thru ALP210 (Floor Mounted) I.
Figure 1B: Alpine™ - Models ALP080 thru ALP210 (Wall Mounted) I.
Figure 1C: Alpine™ - Models ALP285 thru ALP399 (Floor Mounted Only) I.
Figure 1D: Alpine™ - Model ALP500 (Floor Mounted Only) I.
I. Product Description, Specifications and Dimensional Data (continued) Table 2A: Rating Data - Models ALP080 thru ALP500 (0 to 2000 Feet Elevation Above Sea Level) Alpine Series Gas-Fired Boilers * Model Number Input (MBH) Min. Max. ALP080 16 80 ALP105 21 105 ALP150 30 150 ALP210 42 210 ALP285 57 ALP399 80 ALP500 100 ** Output (MBH) 73 Net I=B=R Thermal AFUE Ratings Efficiency % Water (MBH) (%) Combustion Efficiency (%) Boiler Water Heat Transfer Area Volume (Gal.) (Sq. Ft.
I. Product Description, Specifications and Dimensional Data (continued) Table 2C: Rating Data - Models ALP150 thru ALP285 (7001 to 10,000 Feet Elevation Above Sea Level) Alpine Series Gas-Fired Boilers Model Number * Input (MBH) Min. Max. ** Output (MBH) Net I=B=R Thermal AFUE Ratings Efficiency % Water (MBH) (%) Combustion Efficiency (%) Boiler Water Heat Transfer Volume Area (Sq. Ft.) (Gal.) ALP150 38 113 104 90 95 1.3 16.4 ALP210 53 158 145 126 95 1.7 21.
II. Pre-Installation & 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 DOES NOT warrant failures caused by mis-sized boiler applications. DO NOT oversize the boiler to the system.
II. Pre-Installation & Boiler Mounting (continued) 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. In cases where the boiler cannot be centered between the studs, or where the studs are spaced closer than 16” apart, the boiler may be anchored to ¾” plywood or horizontal 2 x 4’s anchored to the studs.
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II. Pre-Installation & Boiler Mounting (continued) n. Place Access Panel Gasket adhesive side (protective paper) down onto Access Panel underside and align gasket edges flush with panel edges. Peel off protective paper from one end of the gasket to expose adhesive, then place the gasket onto the panel aligning gasket and panel side, top and bottom edges, and press the gasket lightly down. Continue peeling of protective paper and positioning the gasket in place while insuring edge alignment.
II. Pre-Installation & Boiler Mounting (continued) Figure 2D: Bottom Mounting Bracket Installation / Boiler Wall Mounting Figure 2E: Access Panel and Gasket Installation III. Unpacking Boiler CAUTION Do not drop boiler. A. Move boiler to approximate installed position. B. Remove all crate fasteners. C. Lift and remove outside container. D. Remove boiler from cardboard positioning sleeve on shipping skid.
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 pipe and fittings is prohibited. Do not use a barometric damper, draft hood or vent damper with this boiler.
IV. Venting (continued) Table 3: Vent/Combustion Air System Options Boiler Build Approved Direct Vent System Vent Material Orientation Figures Component Table Standard (thru sidewall) The system includes separate CPVC vent pipe and PVC air intake pipe terminating thru sidewall with individual penetrations for the vent and air intake piping and separate terminals (tees). 4 thru 9 4A Optional Snorkel (thru sidewall) Same as above but separate snorkel type terminals.
IV. Venting (continued) • • • • • • • • • • • • 20 to prevent nuisance boiler shutdowns. However, boiler may be installed with vertical venting and sidewall combustion air inlet or visa versa, if installation conditions do not allow alternate arrangement. The bottom of the vent and air intake terminal must be at least 12" (18" in Canada) above the normal snow line. In no case should they be less than 12" above grade level.
IV. Venting (continued) B. CPVC/PVC Venting WARNING WARNING When using the CPVC/PVC vent options, the use of CPVC is required when venting in vertical or horizontal chase ways. All CPVC vent components (supplied with boiler) must be used for near-boiler vent piping before transitioning to Schedule 40 PVC pipe (ASTM 2665) components for remainder of vent system. 1. Components and Length Restrictions a.
IV. Venting (continued) Table 4C: CPVC/PVC Vent & Air Intake Components (Installer Provided) required for Optional Horizontal (Snorkel) Termination Quantity Part ALP150& ALP210 ALP285 thru ALP500 ALP080 & ALP105 Number Horizontal (Snorkel) Horizontal (Snorkel) Horizontal (Snorkel) Termination Termination Termination Vent Components 3" Schedule 40 PVC Pipe x up to 7 ft. max. vertical run 4" Schedule 40 PVC Pipe x up to 7 ft. max.
IV. 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) Pipe Dia. (In.) 3 4 Length of Straight Run (Ft.) Loop Length (L) (In.
IV. Venting (continued) Table 7: Vent/Combustion Air Pipe Length – Two-Pipe Direct Vent System Options (CPVC/PVC and Stainless Steel/PVC or Galvanized Steel) Boiler Model 3” Combustion Air Pipe (Equivalent Length) 4” Combustion Air Pipe (Equivalent Length) 3” Vent Pipe (Equivalent Length) 4” Vent Pipe (Equivalent Length) Min. Max. Min. Max. Min. Max. Min. Max. ALP080 30 In. 100 Ft. --- --- 30 In. 100 Ft. --- --- ALP105 30 In. 100 Ft. --- --- 30 In. 100 Ft.
IV. Venting (continued) 4. Near-Boiler Vent/Combustion Air Piping - Floor Mounted Boiler Builds Refer to Figure 6A and the following Steps: a. All CPVC vent components supplied with boiler inside vent carton (3” or 4” Schedule 40 x 30” long CPVC pipe and 3” or 4” Schedule 80 CPVC 90° Elbow) must be used for near-boiler piping before transitioning to Schedule 40 PVC (ASTM 2665) pipe components for reminder of vent system.
IV. Venting (continued) ii. Combustion Air Piping • Do not exceed maximum combustion air length. Refer to Table 7. • Size combustion air wall penetration to allow easy insertion of combustion air piping. • Install Rodent Screen and Combustion Air Terminal (supplied with boiler), see Figure 9 for appropriate configuration. • Apply sealant between vent pipe and opening to provide weather-tight seal. b. Optional Two-Pipe Snorkel Termination Refer to Figures 7, 9 and 10.
IV. Venting (continued) Figure 11: Direct Vent - Vertical Terminations Figure 10: Direct Vent - Optional Sidewall Snorkel Terminations • Install maximum vertical run of seven (7) feet of Schedule 40 PVC vent pipe. See Figure 10. • At top of vent pipe length install another PVC 90° elbow so that elbow leg is opposite the building’s exterior surface. • Install Rodent Screen and Combustion Air Terminal (supplied with boiler), see Figure 9 for appropriate configuration. • Brace exterior piping if required.
IV. Venting (continued) Figure 12: Direct Vent - Vertical Terminations with Sloped Roof Extend vent/combustion air piping to maintain minimum vertical (‘X’) and minimum horizontal (‘Y’) distance of twelve (12) inches (18 inches Canada) from roof surface. Allow additional vertical (‘X’) distance for expected snow accumulation. • • Install Rodent Screen and Vent Terminal (supplied with boiler), see Figure 9 for appropriate configuration. Brace exterior piping if required. ii.
IV. Venting (continued) C. Stainless Steel Venting a. Push the stainless steel vent adapter onto the CPVC/PVC connector with a slight twisting motion. Make sure that the stainless steel vent adapter is inserted at least 1” (refer to Figure 13). 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.
IV. Venting (continued) • • • • Male end of terminal will fit into the female end of any of the approved stainless vent systems. Apply a heavy bead of silicone to the male end of the terminal before inserting it into the last piece of pipe. Orient the terminal so that the seam in the terminal is at 12:00. Smooth the silicone over the seam between the terminal and the last piece of pipe, applying additional silicone if necessary to ensure a tight seal.
IV. Venting (continued) • • 5. Install Rodent Screen (not supplied) and horizontal vent terminal. Brace exterior piping if required. D. Concentric Polypropylene Venting 1. Vent Length Restrictions a. Vent length restrictions are based on equivalent length of vent pipe i.e. total length of straight pipe plus equivalent length of fittings. See Table 9 for specified vent length details. Do not exceed maximum vent length.
IV. Venting (continued) Figure 14: Field Installation of Boiler Concentric Vent Collar 2. Field Installation of Boiler Concentric Vent Collar a. Locate and remove six mounting screws from the Miscellaneous Parts Carton. b. Position the Collar onto jacket combination rear/bottom panel and insert collar inner stainless steel vent pipe into the heat exchanger vent outlet. c.
IV. Venting (continued) Figure 17: Cutting Straight Pipe iv. Make an insertion mark 1” from the male end of the outer pipe. v. Cut the plastic inner pipe so that it will protrude 3/8” beyond the male end of the outer pipe when reinstalled in the outer pipe. Use a fine tooth hacksaw or a PVC saw to cut the plastic pipe and be careful to cut the pipe square. De-burr the cut edge of the plastic pipe with a file, razor blade or fine sandpaper. vi. Reinstall the inner pipe. e.
IV. Venting (continued) iv. Use locking bands (provided with all fittings) to secure non-cuttable pipe, as well as fittings, to the boiler collar (see Figure 19). v. Use the same method to join all remaining vent components except for the terminal. 4. Horizontal Vent Termination a. Standard Concentric Termination Refer to Figure 20. 34 Figure 20: Horizontal Concentric Venting i.
IV. Venting (continued) Figure 22: Cutting Vent Terminal Pipe • Re-install locking band clamp onto the joint to secure the terminal to the collar or the last section of the vent 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 (continued) Figure 23: Completing Horizontal (Wall Terminal Installation) 36 Figure 24: Vertical Concentric Vent Installation • Install the roof flashing using standard • Cut the outer pipe only at the point practice on the roofing system of the marked in Step (e) using aviation shears, structure. a hacksaw, or an abrasive wheel cutter. Be careful to cut the pipe square. De-burr the • If not already done, assemble the venting cut end with a file or emery cloth. system inside the building.
IV. Venting (continued) Figure 25: Dimension "H" Figure 26: Cutting Vertical Terminal • Slip the terminal section through the roof from the outside. Push into the last section of vent pipe until the mark made in Step (h) is not longer visible. Secure the terminal to the last piece of pipe with three #10 x 1/2” sheet metal screws. Drill a 1/8” hole through both outer pipes to start these screws.
IV. Venting (continued) Figure 28: Chimney Chase Installation E. Removing the Existing Boiler For installations not involving the replacement of an existing boiler, proceed to Step B. When an existing boiler is removed from a common venting system, the common venting system is likely to be too large for proper venting of the remaining appliances.
V. Condensate Disposal A. Condensate Trap and Drain Line. 1. All condensate, which forms in the boiler or vent system, collects in the sump under heat exchanger and leaves the boiler through factory installed condensate trap. 2. The trap allows condensate to drain from sump while retaining flue gases in the boiler. The trap has factory installed overflow switch, which shuts down the boiler in the event the drain line becomes obstructed, preventing proper condensate removal.
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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 appliance 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 (continued) 2. Relief Valve Piping, ALP399 and ALP500 Boiler Models a. Locate and remove (2) ¾” NPT x close black nipples, 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. Install the second close nipple into tee run top outlet. d.
VI. Water Piping and Trim (continued) Table 11: Flow Range Requirement Through Boiler Boiler Model Boiler Boiler Minimum Boiler Required Boiler Head Supply Return Required Flow Head Loss, Flow, Loss, Connection, Connection, (GPM) Ft. (GPM) Ft. Inch, FPT Inch, FPT @ 35°F DT @ 35°F DT @ 30°F DT @ 30°F DT Required Maximum Boiler Flow, Boiler Head Required Head Loss, (GPM) Loss, Ft. @ Flow (GPM) Ft. @ 25°F 25°F DT @ 20°F DT @ 20°F DT DT ALP080 1 1 4.2 4.8 4.9 6.4 5.8 8.9 7.3 13.4 ALP105 1 1 5.
VI. Water Piping and Trim (continued) Table 12: Recommended Circulator Models for Alpine (ALP) Boilers Based on 25°F Temperature Differential and Up to 75 ft. Equivalent Length Near-Boiler Piping - Space Heating Circulator Boiler Model Boiler Supply Connection, Inch, FPT Boiler Return Connection, Inch, FPT Near-Boiler Piping Supply Pipe Size, Inch Near-Boiler Piping Return Pipe Size, Inch Flow, GPM @ 25°F Temp. Differential ALP080 1 1 1 1 5.8 10.
VI. Water Piping and Trim (continued) Table 13: Fitting and Valve Equivalent Length Table 13: Fitting and Valve Equivalent Length (cont’d) Copper Fitting and Sweat Valve Equivalent Length (Ft) Fitting or Valve Description Threaded Fitting and Valve Equivalent Length (Ft) Copper Pipe or Valve Size Fitting or Valve Description Black Threaded Pipe or Valve Size 1 1¼ 1½ 2 90° Elbow 2.5 3.0 4.0 5.5 1 1¼ 1½ 2 45° Elbow 1.0 1.2 1.5 2.0 90° Elbow 2.6 3.5 4.0 5.2 Tee (thru flow) 0.
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 12 for recommended Boiler Loop Circulator. Figure 31: Near Boiler Piping - Heating Only VI.
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 12 for recommended Boiler Loop Circulator. Figure 32: Near Boiler Piping - Heating Plus Indirect Water Heater VI.
VI. Water Piping and Trim (continued) WARNING Pressure relief valve discharge piping must be piped such that the potential of severe burns is eliminated. DO NOT pipe in any area where freezing could occur. DO NOT install any shut-off valves, plugs or caps. Consult Local Codes for proper discharge piping arrangement. 2. Circulator (Required) – Usually at least two circulators will be required to properly install a Alpine™ Series boiler. See Paragraph B above for information on sizing the circulators. 3.
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VII. Gas Piping 2. Maximum gas demand. Refer to the boiler’s input as printed on its rating label. Also consider existing and expected future gas utilization equipment (i.e. water heater, cooking equipment). 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.
VII. Gas Piping (continued) WARNING WARNING Failure to use proper thread compounds on all gas connectors may result in leaks of flammable gas. Gas supply to boiler and system must be absolutely shut off prior to installing or servicing boiler gas piping. Table 14B: 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 Pipe Size, In. Inside Diameter, In. Length of Pipe, Ft.
VII. Gas Piping (continued) Table 16: 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 1. Use methods and materials in accordance with local plumbing codes and requirements of gas supplier. In absence of such requirements, follow National Fuel Gas Code, NFPA 54/ANSI Z223.1. 2.
VII. Gas Piping (continued) DANGER Do not use matches, candles, open flames or other ignition source to check for leaks. D. Alpine Model 500 only (if equipped with optional low and high gas pressure switches): 2. For the low and high gas pressure switches proper operation, the boiler inlet gas pressure must be within 4.5” w.c. to 13.5” w.c. range. 3. The gas pressure can be measured at the gas valve inlet pressure port. Refer to Figure 34B. 4.
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.
VIII. Electrical (continued) Low Voltage (24 VAC) Connections - see Figure 35. 3. The terminal block TB-2 in conjunction with terminal screw identification label is attached to the junction box front and located inside Sage2.1 Control compartment on the left side. 4. The connections are (listed identification label top to bottom): a. b. c. d. e. f. g. h. i. j. k. l.
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4 3 2 1 5 4 3 2 1 5 4 3 2 1 5 FLAIR "VJ" ZONE VALVES (SEE NOTE) 2 RD YE 4 1 3 2 RD YE 4 RD YE 1 3 2 3 2 1 2 3 2 1 RD YE 2 RD YE 4 1 3 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.
IX. Boiler Stacking 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 19 “Alpine (ALP) Boiler Model Stacking Combinations” for details.
IX. Boiler Stacking (continued) permissible, providing common pipe has sufficient flow capacity to handle combined condensate volume of stackable combination. 2. Gas Piping - Follow instructions in Section VII “Gas Piping” of the manual for sizing and installation of an individual boiler. When common gas piping is sized, insure it will have adequate capacity for combined input (GPH gas flow) of the selected stackable boiler combination. 3.
X. Modular Installation A. General Guidelines 1. Read and follow all venting, combustion air, water piping, gas piping and electrical instructions contained in this manual, unless otherwise instructed in this section. 2. Consult Local Building Codes or National Fuel Gas Code, NFPA 54/ANSI Z222.3 for restrictions and instructions on modular boiler installations. B. Venting 1. CPVC/PVC Venting a. Modular CPVC/PVC direct venting is shown in Figure 39. b.
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Figure 40: Modular Boiler Concentric Vent Termination X.
X. Modular Installation (continued) e. Individual module (boiler) sidewall concentric vent terminals must be placed at least twelve (12) inches above the ground plus the expected snow accumulation. f. For vertical through the roof venting any adjacent individual module (boiler) vertical vent terminals, if level with each other, must be spaced no closer than 12 inches horizontally. If vertical vent terminals cannot end in one plane, they must be spaced no closer than three (3) feet horizontally. g.
Figure 41A: Modular Boiler Water Piping w/Domestic Hot Water Heater (Page 1of 2) Installing a low water cutoff in the system piping of modular boilers is strongly recommended and may be required by Local Codes. NOTICE B. Keep this distance as short as practical. C. At least 18" of straight pipe for Conventional Air Scoop. X.
Installing a low water cutoff in the system piping of modular boilers is strongly recommended and may be required by Local Codes. NOTICE Figure 41B: Modular Boiler Water Piping w/Domestic Hot Water Heater (Page 2 of 2) X.
Figure 42A: Alternate Modular 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 12 for recommended Boiler Loop Circulator. CAUTION X.
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 21 for recommended Boiler Loop Circulator. CAUTION Figure 42B: Alternate Modular Boiler Water Piping w/Indirect Domestic Hot Water Heater (Page 2 of 2) X.
1 1 1 Boiler Model ALP080 ALP105 ALP150 1 1 1 Boiler Return Connection, Inch, FPT 1 1 1 1 1 1 NearBoiler Piping Return Pipe Size, Inch 13.8 9.6 7.3 Max Allowable Flow thru Boiler, GPM @ 20°F Delta T 11 7.7 5.8 Flow, GPM @ 25°F Delta T 7.9 5.5 4.2 Min Req’d Flow thru Boiler, GPM @ 35°F Delta T 14 SL119 6 SL50 6 6 SL35 SL70 6 SL27 17 10 9.5 9 9 17 10 6 14 SL70 SL119 9.5 9 9 6 6 SL35 SL50 6 SL27 17 10 6 14 SL70 SL119 9.
1 1-1/4 1-1/2 1-1/2 Boiler Model ALP210 ALP285 ALP399 ALP500 1-1/2 1-1/2 1-1/4 1 Boiler Return Connection, Inch, FPT 2 2 1-1/2 1-1/4 2 2 1-1/2 1-1/4 NearBoiler Piping Return Pipe Size, Inch 47.2 37.7 26.5 19.4 Max Allowable Flow thru Boiler, GPM @ 20°F Delta T 37.8 30.2 21.2 15.5 Flow, GPM @ 25°F Delta T 27.0 21.5 15.1 11.
Figure 43: Three Boiler Modular Wiring Diagram Internal Sage2.1 Multiple Boiler Control Sequencer (Three Boilers Shown, Typical Connections for up to Eight Boilers) X.
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. The boilers will modulate based on an Analog communication signal established between the Tekmar 265 Control and each boiler’s Sage2.1™ Control.
The Tekmar 264 Control (or equal) can control up to four (4) boilers and an Indirect Water Heater by utilizing stage firing. When a call for heat is received by the Tekmar 264 Control, the control will fire either one or more boilers in sequential firing mode to establish a required reset water temperature in the system supply main based on outdoor temperature. The boilers will modulate on their own based on each boiler’s Sage2.
X. Modular Installation (continued) WARNING If gas pressure in the building is above ½ psig, an additional gas pressure regulator is required. Using one additional regulator for multiple boilers may result in unsafe boiler operation. The additional regulator must be able to properly regulate gas pressure at the input of the smallest boiler. If the regulator cannot do this, two or more additional regulators are required.
X. Modular Installation (continued) G. Modular Boiler Operating Information 1. Major Features a. “Plug & Go” Multiple Boiler Control Sequencer When multiple boilers are installed, the Sage2.1’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. b. Sequencer Master A single Sage2.
X. Modular Installation (continued) k. Advanced Boiler Sequencing After there is a Call For Heat input, both header water temperature and boiler firing rate percent are used to start and stop the networked boilers. The control starts and stops boilers when the water temperature is outside the user selected “Diff Above” and “Diff Below” settings. Also, in order to minimize temperature deviations, the control adjusts the number of boilers running based on the firing rate.
X. Modular Installation (continued) G. Modular Boiler Operating Information (continued) 2. Operating Mode a. Sequencer Status Screen The “Sequencer Status” screen, shown in Figure 46, appears on the Sage2.1 Controller when the Sequence Master is enabled and the “Home” screen “Status” button is selected. The screen is added to the existing status screens already offered by the Sage2 controller. The following information is provided on this screen: i.
X. Modular Installation (continued) G. Modular Boiler Operating Information (continued) 2. Operating Mode (continued) b. Networked Boilers Detail Screens The “Networked Boilers” detail screen, shown in Figure 47, is available on the Sage2.1 Controller when the Sequence Master is enabled and the “Home” screens “Detail” button is selected. The screen is added to the existing detail screens already offered by the Sage2 controller. The following information is provided on this screen: i.
X. Modular Installation (continued) G. Modular Boiler Operating Information (continued) 3. 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 41A and 42A for installation location and Figure 48 or 49 for installation detail. b.
X. Modular Installation (continued) G. Modular Boiler Operating Information (continued) 3. Required Equipment and Setup d. Modular Boiler Setup Step 1 2 3 4 5 6 7 8 9 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.
X. Modular Installation (continued) G. Modular Boiler Operating Information (continued) 4. Adjusting Parameters From the “Home” screen select the Adjust button to access the adjust mode screens links (if required refer to “Entering Adjustment Mode”, Section XII, Paragraph D, 4 for login in instructions).
X. Modular Installation (continued) G. Modular Boiler Operating Information (continued) 4.
X. Modular Installation (continued) G. Modular Boiler Operating Information (continued) 4. Adjusting Parameters (continued) Example Pump Parameter selections (continued): b.
XI. System Start-up A. Verify that the venting, water piping, gas piping and electrical system are installed properly. 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. WARNING Completely read, understand and follow all instructions in this manual before attempting start up. D.
XI. 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 Test flame circuit then checks for flame signal. Drive Purge Driving blower to purge rate setting and waiting for the proper fan feedback.
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XI. System Start-up (continued) Figure 52: Burner Flame WARNING Table 23: Recommended Combustion Settings, Natural Gas Altitude Range Boiler Model 0 - 7000 Ft. % CO2 % O2 Range 8.7 - 7.3 (High Fire) 5.6 - 8-.0 (High fire) CO, PPM ALP080 ALP105 ALP150 ALP210 ALP285 ALP399 10.1 - 6.6 (Low Fire) 3.2 - 9.2 Less than 100 PPM (Low Fire) ALP500 L. Test External Limits Test any external limits or other controls in accordance with the manufacturer’s instructions. M.
XI. System Start-up (continued) 4. Before attempting to start the boiler, make the number of turns to the throttle screw called for in Table 24. 5. Attempt to start the boiler using the lighting instructions located inside the lower front cover of the boiler. If the boiler does not light on the first try for ignition, allow to boiler to make at least four more attempts to light.
XI. System Start-up (continued) 7. Perform a combustion test. Refer to Paragraph K above for details. To increase the CO2 (reduce the O2) turn the throttle counter-clockwise Make adjustments in increments of 1/8 to 1/4 turn and allow the boiler at least a minute to respond to each adjustment before making another. In general, the CO level will be at its lowest somewhere in the CO2 range shown in this table. • 8.
XII. Operation A. Major Features 1. General The Sage2.1™ Control provides safety interlocks and water temperature control. The Sage2.1 simply controls boiler modulation and pump outputs based on the boiler water outlet temperature and a contractor adjusted setpoint.
XII. Operation (continued) 7. Priority Demand The Sage2.1 accepts a call for heat (demand) from multiple places and responds to each demand according to it’s relative importance. When more than one demand is present at one time the more important demand is selected as the “priority” demand and is used to operate the boiler and pumps. The selected priority demand is displayed on the boiler “Status” screen (see Figure 55).
XII. Operation (continued) A. Major Features (continued) 8. Boiler Temperature Regulation a. Overview Based on the call for heat type, the Sage2.1 selects a firing rate target temperature setpoint. Sensed temperature is compared to this Setpoint to both adjust firing rate output and along with the corresponding “Diff Above” and “Diff Below” settings cycle the boiler. b.
XII. Operation (continued) A. Major Features (continued) 9. Boiler Protection Features a. 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 Sage2.1 monitors a supply water temperature sensor that is also mounted in the supply water manifold and supplies an internal, manual reset high limit.
XII. Operation (continued) B. Operating Mode 1. Home Screen Under normal conditions, the boiler display shows the “Home” screen and the display looks like that shown in Figure 54. The temperature value shown is the boiler’s supply temperature. Boiler status is shown below the supply water temperature. The “Home” screen provides the following “Buttons” and information: a.
XII. Operation (continued) B. Operating Mode (continued) 2. Boiler Status Screen The “Status” screen, shown in Figure 55, provides an overview of boiler operation. The following information is provided on this screen: a. Boiler Status Boiler status can be found on the “Home” screen and at the bottom of the first “Status” screen. Table 28 shows each status and the action the control takes during the condition. b.
XII. Operation (continued) C. Controls Startup Check List The Sage2.1 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.
XII. Operation (continued) D. User Interface 1. Using The Display The Sage2.1 uses a state-of-the-art touch screen display. The following is a display arrangement overview: Figure 56: Display Arrangement Overview Note: The “Home Screen” is the default screen. Any screen left untouched for more than four minutes will revert to the home screen. 2. Selecting View Mode options Dynamic Value (live data): Measured temperatures are shown throughout the user interface.
XII. Operation (continued) D. User Interface (continued) 3. Help Screens The “Help” screen provides access to active faults, lockout history, the service contact and the boiler reset button. The “Help” screen is accessed from the “Home” screen. 100 Limit String Status Display This display is provided to identify the cause of an Interlock input “open” contact (refer to Figure 36 Ladder Diagram, Interlock input terminal J5-1). For example, this illustration depicts the “Float Switch” contact as “open.
XII. Operation (continued) D. User Interface (continued) Adjust Mode 4. Entering Adjust Mode The “Adjust mode” screen is accessed from the “Home” screen. The “Adjust Mode” provides contractors access to view and adjust additional information. a. Entering Adjustment Mode The Sage2.1 is factory programmed to include basic modulating boiler functionality. These settings are password protected to discourage unauthorized or accidental changes to settings.
XII. Operation (continued) E. Adjusting Parameters 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 Sage2.1’s adjustable parameters. Parameters are presented in the order they appear on the Sage2.
XII. Operation (continued) E. Adjusting Parameters (continued) “Press” Modulation Setup Factory Setting button to access the following parameters: Range / Choices Parameter and Description See Table 30 See Table 30 Boiler Type The Boiler Type parameter changes the parameters listed in Table 30. Factory level password is required. This parameter is intended to allow a user to set the parameters in a spare part Sage2.1 to a particular boiler type.
XII. Operation (continued) E. Adjusting Parameters (continued) “Press” Pump Setup button to access the following parameters: Factory Setting Any Demand Any Demand Range / Choices Parameter and Description Never, Any Demand, Central heat, No Priority, Central Heat, Optional Priority 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.
XII. Operation (continued) E. Adjusting Parameters (continued) Example Pump Parameter selections: a. Single boiler with no Indirect Water Heater System Circulator(s) To System Boiler Circulator Parameter Selections: System Pump= “any demand” Boiler Pump = “any demand” DHW Pump = “never” Explanation: This piping arrangement only services central heat. When there is any demand both boiler and system pumps turn on. Header Temperature Sensor (When Used) b.
XII. Operation (continued) E. Adjusting 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.
XII. Operation (continued) E. Adjusting Parameters (continued) Outdoor Reset “Press” Factory Setting Enabled button to access the following parameters: Range / Parameter and Description Choices Enable Disable 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.
XII. Operation (continued) E.
XII. Operation (continued) E. Adjusting Parameters (continued) “Press” Factory Setting Remote 4-20mA button to access the following parameters: Range / Choices Parameter and Description Local, 4-20mA Central Heat Modulation Source This parameter enables the 4-20mA input to control firing rate and the thermostat input to control boiler on/off demand directly without using internal setpoint. The 4-20mA selection is used to enable a remote multiple boiler controller to control the Sage2.
XIII. 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.
XIII. 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 ignition electrode and inspect it for oxides. Clean the oxides from the electrode with steel wool. Do not use sandpaper for the cleaning. Inspect the ceramic insulator for cracks and replace the ignitor assembly if necessary. Check the ignitor electrode spacing gap.
XIII. Service and Maintenance (continued) b. Equivalent system freeze protection products may be used in lieu of product referenced above. In general, freeze protection for new or existing systems must use specially formulated glycol, which contains inhibitors, preventing the glycol from attacking the metallic system components. Insure that system fluid contains proper glycol concentration and inhibitor level.
XIII. 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.
XIV. Troubleshooting WARNING Turn off power to boiler before working on wiring. A. Troubleshooting problems where no error code is displayed. Condition Possible Cause Display Blank, Fan off, LWCO lights off, no green power light on Sage2.1 Controller No 120VAC Power at boiler. Check breaker and wiring between breaker panel and boiler. Display Panel Blank, Fan running • • • Loose 120VAC connection wiring between boiler J-Box and transformer Loose 24 Vac connection wiring between transformer and Sage2.
XIV. Troubleshooting (continued) B. Troubleshooting problems where a Soft Lockout 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. Code is displayed.
XIV. Troubleshooting (continued) C. Troubleshooting problems where a Hard Lockout “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. Code is displayed. When a hard lockout occurs, the boiler will shut down, the display will turn red and the “Help” button will “blink”.
XV. 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. Key No. Description (Quantity) Part Number ALP080 ALP105 ALP150 ALP210 ALP285 ALP399 1 Heat Exchanger, Burner, Etc.
XV. Repair Parts (continued) Key No. --23 24 25 26 27 28 29 118 Description ALP080 MCBA Control Sage2.1 Control Gas Train Assembly (Key No’s 23 thru 29) Gas Valve Flange Kit Blower Blower Inlet Shroud Assembly Blower Outlet Gasket Blower Mounting Plate Gas Valve MCBA Control Gas Valve Harness with Plug Sage2.
XV. Repair Parts (continued) Key No. Description 35 36 37 38 39 40 41 104 105 106 Air Pressure Switch Air Pressure Switch Hose Rubber Grommet, Condensate Trap Condensate Trap, Blow Molded Spring Clip, Condensate Trap Blocked Condensate Drain Switch Condensate Comp.
XV. Repair Parts (continued) Key No. Description Wiring Harness (Not Shown) Control Panel Assembly (Programmed 43A 0-2000’ or 0-7000’) (Includes all parts shown) Control Panel Assembly (Programmed 43B 2000’ or 7000’) (Includes all parts shown) Control Panel Assembly (Programmed 43C 7001’ - 10,000’) (includes all parts shown) 44 Programmed Display (with Mounting Hardware) 45 Jacket, Upper Front Panel 46 Sage2.1 (Programmed) 47 Sage2.1 Transformer 48 Control Panel, Sage2.
XV. Repair Parts (continued) Key No.
XV. Repair Parts (continued) Quantity Key No.
XV. Repair Parts (continued) Key No.
XV. 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 ALP080 thru ALP210 (Floor Mounted) Figure 1B 8 Models ALP080 thru ALP210 (Wall Mounted) Figure 1C 9 Models ALP285 thru ALP399 (Floor Mounted Only) Figure 1D 10 Model ALP500 (Floor Mounted Only) Section II - Pre-Installation & Boiler Mounting Figure 2A 15 Clearances To Combustible and Non-combustible Material, Floor Standing Figure 2B 15 Clearanc
Appendix A - Figures (continued) Figure Number Page Number Description SectionV - Condensate Disposal Figure 29 40 Condensate Trap and Drain Line Section V - Water Piping and Trim Figure 30 41 Factory Supplied Piping & Trim Installation Figure 31 46 Near Boiler Piping - Heating Only (with Central Heating Circulators) Figure 32 47 Near Boiler Piping - Heating Plus Indirect Water Heater Figure 33 49 Isolation of the Boiler From Oxygenated Water with A Plate Heat Exchanger Section VII - Gas P
Appendix A - Figures (continued) Figure Number Page Number Description Section XI - System Start-Up Figure 51 88 Lighting Instructions Figure 52 89 Burner Flame Figure 53 90 Dungs Gas Valve Detail Section XII - Operation Figure 54 96 Home Screen Figure 55 97 Status Screen Figure 56 99 Display Arrangement Overview Figure 57 108 Outdoor Reset Curve Section XIII - Service and Maintenance Figure 58 111 Ignitor Electrode Gap Figure 59 112 Condensate Overflow Switch Orientation 128
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 & 1D) Table 2A 11 Rating Data - Models ALP080 thru ALP500 (0 to 2000 Feet Elevation Above Sea Level) Table 2B 11 Rating Data - Models ALP080 thru ALP500 (2001 to 7000 Feet Elevation Above Sea Level) Table 2C 12 Rating Data - Models ALP150 thru ALP285 (7001 to 10,000 Feet Elevation Above Sea Level) Section IV - Venting Ta
Appendix B - Tables (continued) Table Number Page Number Description Section XI - System Start-Up Table 23 89 Recommended Combustion Settings, Natural Gas Table 24 90 Number of Clockwise Throttle Screw Turns for LP Conversions Table 25 91 Recommended Combustion Settings, LP Gas Section XII - Operation Table 26 93 Order of Priority Table 27 95 Frost Protection Table 28 96 Boiler Status Table 29 97 Boiler Priority Definitions Table 29 103 Parameters Changed Using the Boiler Type Para
SERVICE RECORD DATE SERVICE PERFORMED 131
Limited Warranty Subject to the terms and conditions set forth below, U.S. Boiler Company, Inc. Lancaster, Pennsylvania hereby extends the following limited warranties to the original owner of a residential grade water or steam boiler or U.S. Boiler Company, Inc. supplied parts and/or accessories manufactured and shipped on or after July 1, 2008: ONE YEAR LIMITED WARRANTY ON RESIDENTIAL GRADE BOILERS AND PARTS / ACCESSORIES SUPPLIED BY U.S. BOILER COMPANY, INC. U.S. Boiler Company, Inc.