Energy Star ALP080B Installation, Operating And Service Instructions Download Page 121

Page: 121 / 136

103448-02 - 6/13

121

Key

no. Description

(Quantity) Part number

aLP080B aLP105B aLP150B aLP210B aLP285B

aLP399

Bare Heat Exchanger

101931-01

101931-02

101931-03

101931-04

101931-05

101931-06

Burner Head Assembly

101933-01

101933-02

101933-03

101933-04

101933-05

101933-06

Replacement Igniter Kit

103005-01

Replacement Flame Sensor Kit

103339-01

Replacement Partially Assembled Burner Door

102696-01

Air Vent Valve

101586-01

Water Temp Sensor

(2) 101685-01

High Limit

101653-01

Gasket, Header (All Three)

101240-01

N/A

Gasket, Header, 1” NPT

N/A

101243-01

N/A

Gasket, Header, 1” & 3/4” NPT

N/A

101252-01

N/A

Gasket, Header, 1-1/2” NPT

N/A

101372-02

101372-03

Gasket, Header, 3/4” NPT

N/A

101372-01

Gas/Air Intake Duct Assembly

101725-01

101725-02

Burner Plate Insulation

(Warning: Contains RCF

101728-01

Burner Plate Inner Seal

101729-01

Burner Plate Outer Seal

101730-01

Burner Head

101731-01

101731-02

101731-03

101731-04

101731-05

101731-06

Burner Head Seal

101732-01

Insulation Disc

(Warning: Contains RCF)

101996-01

101996-02

M6x1 Hex Flange Nut (Not Shown)

(6) 101724-01

M5x14 mm Pan Hd Thread Forming Screw, T25 Drive

(Not Shown)

(4) 101742-01

M5x10mm Pan Hd Thread Forming Screw, Phillips Drive

(Not Shown)

N/A

Thermal Link Switch (Backside of Duo Heat Exchanger)

(Not Shown)

N/A

103321-01

Burner Door Thermostat with Manual Reset (Not Shown)

N/A

104569-01

Flue Exit Gasket Kit (Gasket is Inside of Vent Termination

of Heat Exchanger), (Not Shown)

104500-01

104501-01

Xiii. repair Parts

(continued)

Summary of Contents for ALP080B

Page 1: ...e or maintenance can cause property damage injury or loss of life For assistance or additional information consult a qualified installer service agency or the gas supplier This boiler requires a special venting system Read these instructions carefully before installing 9700609 D N A G N I T A R E P O N O I T A L L A T S N I R O F S N O I T C U R T S N I E C I V R E S E N I P L A Y C N E I C I F F ...

Page 2: ...rs website http license reg state ma us pubLic pl_products pb_pre_form asp for the latest Approval Code or ask your local Sales Representative The Commonwealth of Massachusetts requires this product to be installed by a Licensed Plumber or Gas Fitter DANGER Indicates an imminently hazardous situation which if not avoided will result in death serious injury or substantial property damage CAUTION In...

Page 3: ...late shall be permanently mounted to the exterior of the building at a minimum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS 4 A final inspection by the state or loc...

Page 4: ...arms should be installed on the heating system to prevent damage if the boiler is inoperative This boiler contains very hot water under pressure Do not unscrew any pipe fittings nor attempt to dis connect any components of this boiler without positively assuring the water is cool and has no pressure Always wear protective clothing and equipment when installing starting up or servicing this boiler ...

Page 5: ...ater Piping and Trim 52 VII Gas Piping 67 VIII Electrical 71 IX System Start up 83 X Operation 91 A Overview 91 B Supply Water Temperature Regulation 92 C Boiler Protection Features 93 D Multiple Boiler Control Sequencer 94 E Boiler Sequence of Operation 95 1 NormalOperation 95 2 Using The Display 96 F Viewing Boiler Status 97 1 Status Screens 97 2 Detail Screens 98 3 Multiple Boiler Sequencer Scr...

Page 6: ...ot water heating etc Dimension Boiler Model ALP080B 1 ALP105B 1 ALP150B 1 ALP210B 1 ALP285B 2 ALP399 2 A Inch mm 12 9 16 320 14 356 19 11 16 500 23 15 16 608 21 13 16 554 28 7 8 734 B Inch mm 5 5 8 142 5 13 16 147 7 5 16 185 6 3 16 157 C Inch mm 7 5 16 186 14 1 8 358 13 1 16 332 D Inch mm 9 5 16 237 10 3 4 273 16 7 16 417 17 1 8 435 18 456 23 3 4 602 E Inch mm 5 15 16 151 12 1 4 312 15 13 16 402 G...

Page 7: ...103448 02 6 13 7 Figure 1A Alpine Models ALP080B thru ALP210B Floor Mounted I Product Description Specifications and Dimensional Data continued ...

Page 8: ...8 103448 02 6 13 Figure 1B Alpine Models ALP080B thru ALP210B Wall Mounted I Product Description Specifications and Dimensional Data continued ...

Page 9: ...103448 02 6 13 9 Figure 1C Alpine Models ALP285B thru ALP399 Floor Mounted Only I Product Description Specifications and Dimensional Data continued ...

Page 10: ... the Installation Operating and Service Instructions manual for detailed procedure Ratings shown are for installations at sea level and elevations up to 2000 Feet For elevations above 2000 Feet ratings should be reduced at the rate of four percent 4 for each 1000 Feet above sea level Alpine Series Gas Fired Boilers Model Number Input MBH Boiler Water Volume Gal Heat Transfer Area Sq Ft Min Max ALP...

Page 11: ...ed and skilled personnel from a qualified service agency E Move boiler to its permanent location Alpine Series Gas Fired Boilers Model Number Input MBH Boiler Water Volume Gal Heat Transfer Area Sq Ft Min Max 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 Notes Maximum Working Pressure Water 30 PSI S...

Page 12: ...ystems and Air Supply for Appliances III Pre Installation and Boiler Mounting WARNING Adequate combustion and ventilation air must be provided to assure proper combustion F The boiler should be located so as to minimize the length of the vent system The combustion air piping or the optional concentric vent piping containing integral combustion air inlet piping must terminate where outdoor air is a...

Page 13: ...s been selected for the boiler and any needed modifications have been made to the wall use Figure 2C to locate and layout holes A and B These holes must be positioned on mounting stud centers if the boiler is installed on a framed wall Make sure that the horizontal centerline of these holes is level Holes C and D may also be drilled at this time or after the boiler is hung on the wall If the 5 16 ...

Page 14: ... Figure 2A Clearances To Combustible and Non combustible Material Floor Standing Figure 2B Clearances To Combustible and Non combustible Material Wall Mounted III Pre Installation and Boiler Mounting G General continued ...

Page 15: ...Boiler Builds for instructions on attaching the vent system to the boiler WARNING Vent pipe must be inserted firmly into vent connector and secured by tightening the metal strap worm screw 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...

Page 16: ...BOTTOM SECURING BRACKET 5 16 X 2 LAG SCREW 4X 5 16 X 2 FLAT WASHER 4X 2 X 4 WALL STUD 16 C C BOILER HANGING BRACKET BOILER 8 X 1 2 SMS 2X 1 2 SHEET ROCK BOILER HANGING BRACKET BOTTOM SECURING BRACKET Figure 2E Access Panel and Gasket Installation III Pre Installation and Boiler Mounting G General continued ...

Page 17: ...er boiler left side panel at the panel lower left corner and align bracket two upper holes with corresponding side panel lower dimples The remaining lower bracket hole must align with a matching bottom boiler left side panel top positioning dimple Once bracket holes and side panel dimple alignment is verified attach the bracket to top and bottom boiler left side panels with the mounting screws e R...

Page 18: ...combined input CFH gas flow of the selected stackable boiler combination III Pre Installation and Boiler Mounting H Boiler Stacking continued c Water Piping and Trim Follow instructions in Section VI Water Piping and Trim of the manual for system piping and boiler secondary piping selection sizing based on combined heating capacity and or gross output of the selected stackable boiler combination F...

Page 19: ...mbustion air pipe must maintain a minimum per foot slope down towards terminal when possible If not slope toward boiler 6 Do not install venting system components on the exterior of the building except as specifically required by these instructions refer to Figure 4 a Vent terminals must be at least 1 foot from door window or gravity inlet into the building WARNING Failure to vent this boiler in a...

Page 20: ... vent and air intake piping and separate terminals tees 6 7A 7B 9 9A 9B 10 14 15 9 10 C Optional Snorkel thru sidewall Same as above but separate snorkel type terminals 11 14 15 9 10 Optional Vertical Vertical thru roof or chimney chase The system includes separate Flexible Polypropylene vent liner and Rigid Polypropylene vent pipe combination for venting and Rigid Polypropylene or PVC air intake ...

Page 21: ...ld they be less than 12 above grade level d The bottom of the vent terminal must be at least 7 feet above a public walkway e Do not install the vent terminal directly over windows or doors f The bottom of the vent terminal must be at least 3 feet above any forced air inlet located within 10 feet g A clearance of at least 4 feet horizontally must be maintained between the vent terminal and gas mete...

Page 22: ...e resistance rating requirement may not need to be met but is recommended 10 Multiple individual module vertical vent pipes may be piped through a common conduit or chase so that one roof penetration may be made IV Venting A General Guidelines continued B CPVC PVC Venting WARNING CPVC vent components must be used within any interior space where air cannot circulate freely such as air inside a stud...

Page 23: ...pipe ends for joining and using the primer and the cement 3 Field Installation of CPVC PVC Two Pipe Vent System Connector Floor Mounted Boiler Builds Refer to Figure 6 and Steps below a Position the CPVC PVC vent connector and gasket onto boiler rear bottom panel and insert vent connector inner stainless steel vent pipe into heat exchanger vent outlet IV Venting B CPVC PVC Venting continued b Alig...

Page 24: ...lication instructions provided on primer and cement bottles 5 Field Installation of CPVC Vent Pipe Wall Mounted Boiler Builds Refer to Figure 7B and the following Steps The wall mounted boiler builds do not require using 3 Schedule 80 CPVC 90 Elbow for near boiler vent piping a Insert provided 3 Schedule 40 x 30 long CPVC pipe thru air box top combination vent combustion air collar vent opening an...

Page 25: ... Straight Run Ft Loop Length L In 3 20 53 30 65 40 75 50 84 60 92 4 20 60 30 74 40 85 50 95 60 104 Table 7 Expansion Loop Lengths WARNING Apply supplied silicon dielectric grease from attached pouch to gasket inside vent section of two pipe vent connector Failure to apply the grease could result in gasket rupture during vent pipe installation and gasket deterioration due to condensate exposure Che...

Page 26: ...ength Ft Pc Subtotal Equivalent Ft D 3 10 3 1 10 10 4 13 4 1 13 13 45 Elbow s PVC Installer Supplied 90 Elbow s PVC Installer Supplied Nominal Diameter In Quantity Pc Equivalent Length Ft Pc Subtotal Equivalent Ft B Nominal Diameter In Quantity Pc Equivalent Length Ft Pc Subtotal Equivalent Ft A 3 3 0 3 10 4 4 5 4 13 Straight Pipe PVC Installer Supplied 45 Elbow s PVC Installer Supplied Nominal Di...

Page 27: ...permit adequate air circulation around the outside of the pipe to prevent internal wall temperature rising above ANSI Z21 13 standard specified limit Do not enclose PVC venting use higher temperature rated CPVC pipe in enclosed spaces or to penetrate combustible or non combustible walls PVCventpipemaynotbeusedtopenetrate combustible or non combustible walls unless all following three conditions ar...

Page 28: ...pening to provide weather tight seal CAUTION To avoid cross contamination extend the distance between adjacent vent terminations Figure 9A Direct Vent Sidewall Terminations b Optional Two Pipe Snorkel Termination See Figures 10 and 11 Thisinstallationwillallowamaximumofseven 7 feet vertical exterior run of the vent combustion air pipingtobeinstalledontheCPVC PVChorizontal venting application NOTIC...

Page 29: ...l Snorkel Terminations 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 min...

Page 30: ...onsforinstallationprocedures Extendcombustionairpipetomaintain minimum vertical and horizontal distance of twelve 12 inches from roof surface Allow additional vertical distance for expected snow accumulation Provide brace as required Install storm collar on combustion air pipe immediately above flashing Apply Dow Corning Silastic 732 RTV Figure 12 Direct Vent Vertical Terminations Extend vent comb...

Page 31: ... PVC to PP Boiler Adapter Connector Rigid Pipe Flex Pipe Pipe Joint Locking Band Side Wall Termination Tee Chimney Kit for Venting Only ALP080B ISAA0303 ISSAL0303 N A 80 mm 80 mm IANS03 ISTT03 IFCK0325 and IFCK0335 ALP105B ALP150B ISAA0303 ISSAL0303 ISAA0404 ISSAL0404 80 mm and 110 mm 80 mm and 110 mm IANS03 and IANS04 ISTT03 and ISTT04 ALP210B ALP285B ISAA0404 ISSAL0404 110 mm 110 mm IANS04 ISTT0...

Page 32: ...pter M G DuraVent Shown regarding application listing permits minimum clearances to combustibles installation details proper joint assembly pipe support and routing gasket and fitting installation optional tooling availability usage routing thru masonry chimney for combustion product venting or combination of combustion product venting and combustion air supply When there is a conflict between fle...

Page 33: ...ipe x 1 ft 1 Rigid Single Wall 100 mm 110 mm Polypropylene Pipe x L ft long Multiply L by 1 Flexible 80 mm Polypropylene Pipe x 1 ft 1 2 Flexible 80 mm Polypropylene Pipe x L ft long Multiply L by 1 2 Flexible 100 mm 110 Polypropylene Pipe x 1 ft 1 2 Flexible 100 mm 110 Polypropylene Pipe x L ft long Multiply L by 1 2 Figure 15 Field Installation Procedure to Accept Polypropylene Vent Piping Wall ...

Page 34: ...t Subtotal Equivalent Ft B 80 1 80 1 100 110 1 100 110 1 Total Equivalent Length Ft A B C Total Equivalent Length Ft A B C 2 5 Add 2 5 ft 30 Straight Pipe CPVC Supplied with Boiler if used 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 PushandtwistPVCtoPPboileradapter ISAA0303 or ISAA0404 as a...

Page 35: ...DuraVent vent system only to secure PVC to PP adapter to a coupling and a polypropylene rigid pipe either venting and or air intake Table 11 provides polypropylene venting or combustion air supply system component equivalent length values to calculate the equivalent vent length Venting of Other Appliances or Fireplace into Chase or Adjacent Flues Prohibited Optional Two pipe Vertical Venting Insta...

Page 36: ...ufacturers 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 Where one of the multiple flues is being used for an appliance venting the flexible vent installation is not permitted thru any of adjacent flu...

Page 37: ...a Vent length restrictions are based on equivalent length of vent combustion air pipe total length of straight pipe plus equivalent length of fittings Maximumvent combustionairlengthsarelistedin Table8 Donotexceedmaximumvent combustion air lengths Do not include vent combustion air terminals in equivalent feet calculations See Combustion Air Vent Equivalent Length Work Sheet b The vent termination...

Page 38: ...eries III Z Vent III 3 2SVSWTEF03 Tee 2SVSTTF03 24SVSTPF03 4 2SVSWTEF04 Tee 2SVSTTF04 24SVSTPF04 Flex L Intl Star 34 3 SR03WT15 Tee SRTT 03 SRTP 03 4 SR04WT15 Tee SRTT 04 SRTP 04 NOTE See vent system manufacturer s literature for other part numbers that are required such as straight pipe elbows firestops and vent supports Table 13B Alternate Vent Systems and Vent Components Stainless Steel Install...

Page 39: ...Chase Bracket 100 150 mm 10 0 See Note 3 101561 01 Hanger Wall Bracket 100 150 mm 103097 01 Locking Clamp 100 150 mm Notes NA do not include vent terminal into total vent length calculations These sections have plain male end and beaded female end See Figure 19 for details These sections have beaded male end and beaded female end See Figure 20 for details 1 Vertical terminal can be used with eithe...

Page 40: ... Installation of Boiler Concentric Vent Collar i Determine the required length of the outer pipe When doing this allow an additional 1 of length for insertion into the female end of the adjoining pipe Mark the cut line on the outer pipe ii Remove the plastic inner pipe by pulling it out from the female end iii Cut the OUTER PIPE ONLY at the point marked in Step a using aviation shears a hacksaw or...

Page 41: ...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 Do not use a sheet metal screw longer than 1 2 see Figure 23 Figure 22 Joining Cuttable Pipe Figure 23 Joining Non Cuttable Pipe iv Use locking bands provided with all fittings to secure non cuttable pipe as well as fittings to the ...

Page 42: ...eeFigure24 Horizontal Concentric Venting iv Install the Horizontal Wall Terminal Cut a 5 diameter hole through the exterior wall opening for 80 125 mm concentric vent or6 for100 150mm attheplanned location of the horizontal terminal Measure dimension L from exterior wall outer surface to the end of the last fitting See Figure 25 Dimension L When factory Horizontal Wall Terminal needs to be shorten...

Page 43: ...ateontothe shortenedHorizontal Wall Terminalinterior end and move the plate to cover interior wall cut opening Secure the plate with provided fasteners then applythesealantaroundplate sides to seal it to interior wall refer to Figure 27 Lubricate the brown gasket inside boiler concentric vent collar or the last section of the vent pipe with small amount of water Ensurethatinnerpipeoftheterminalise...

Page 44: ...n 3 8 into the outer pipe Do not use a sheet metal screw longer than 1 2 Secure the terminal section to the inside of theroofstructureusingthemountingbracket provided with the terminal Figure 31 b Optional Concentric Chimney Chase Installation Refer to Figure 32 i A vertical concentric vent system can be installed in an UNUSED masonry chimney The Chimney chase Support Elbow with attachedMountingBr...

Page 45: ...3 45 IV Venting F Removing the Existing Boiler continued Figure 28 Vertical Concentric Vent Installation Figure 29 Dimension H Figure 30 Cutting Vertical Terminal Figure 31 Completing Vertical Terminal Installation ...

Page 46: ...elle 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 Dans la mesure du possible fermer toutes les portes et les fenêtres du bâtiment et toutes les portes entre l espace où les appareils toujours racco...

Page 47: ...103448 02 6 13 47 Figure 33 Multiple Boiler Direct Vent Termination IV Venting G Multiple Boiler Installation Venting continued ...

Page 48: ...ntally If vertical vent terminals cannot end in one plane they must be spaced no closer then three 3 feet horizontally 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...

Page 49: ...103448 02 6 13 49 IV Venting G Multiple Boiler installation Venting continued Figure 34 Multiple Boiler Concentric Vent Termination ...

Page 50: ...rnal high limit to shut off the boiler and if desired in series with installer supplied alarm to trigger an alarm in the event of overflow d Do not attempt to substitute another trap for one provided with the boiler 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 a...

Page 51: ...able as optional equipment Follow local codes and instructions enclosed with the kit for Condensate Neutralizer installation 3 Limestone chips will get coated by neutral salts product of chemical reaction between limestone and acidic condensate and lose neutralizing effectiveness over time Therefore periodic condensate neutralizer maintenance and limestone chip replacement must be performed A pH t...

Page 52: ...s 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 Boiler Company s Standard Warranty does not cover problems caused by oxygen contamination of boiler water or scale lime build up caused by frequent additi...

Page 53: ...ng sure branch outlet is in horizontal plane and facing the boiler front c Install x NPT black reducing bushing into the tee branch then put inTemperature Pressure Gauge B Piping System To Be Employed Alpine ALP boilers are designed to operate in a closed loop pressurized system Minimum pressure in the boiler must be 12 PSI Proper operation of the Alpine ALP boiler requires that the water flow thr...

Page 54: ...lators Table 16 Flow Range Requirement Through Boiler Alpine Boiler Head Loss vs Flow 80 105 150 210 285 399 500 0 5 10 15 20 25 0 5 10 15 20 25 30 35 40 45 50 Flow Rate GPM Boiler Head Loss Feet VI Water Piping and Trim B Piping System To Be Employed continued 2 Direct connection of Alpine ALP boiler to heating system similar to a conventional boiler is NOT RECOMMENDED because a The flow rate thr...

Page 55: ...tes a Grundfos circulator Example Boiler part number ALP105BW 2T02 indicates Alpine boiler equipped with Taco Circulator Boiler part number ALP105BW 2G02 indicates Alpine boiler equipped with Grundfos Circulator C Standard Installation Requirements Observe the following guidelines when making the actual installation of the boiler piping 1 Safety Relief Valve Required The relief valve is packaged l...

Page 56: ... Before connecting the boiler insure the system is free of impurities grease sediment construction dust sand copper dust flux and any residual boiler water additives Flush the system thoroughly and repeatedly if needed with clear water mixed with concentrated rinse agent to remove these contaminants completely Iron oxide red oxide sludge Fe2 O3 is produced during oxygenation To minimize any oxygen...

Page 57: ... Standard Installation Requirements continued 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 ...

Page 58: ... and Trim C Standard Installation Requirements continued 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 ...

Page 59: ...s 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 WARNING Safety 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 o...

Page 60: ...gh an Alpine model boiler to an indirect water heater Alliance SL model coil flow rate required to achieve water heater rating Refer to Table 20 and Figures 41A and 41B a When Alliance SL model coil flow rate required to achieve water heater rating falls within the specified flow range for Alpine boiler model the Alliance SL model can be piped as part of Alpine near boiler piping Refer to Table 20...

Page 61: ...iple Boiler Installation continued Figure 40A Multiple Boiler Water Piping w Domestic Hot Water Heater Page 1 of 2 NOTICE Installing a low water cutoff in the system piping of multiple boilers is strongly recommended and may be required by Local Codes ...

Page 62: ...r Piping w Domestic Hot Water Heater Page 2 of 2 VI Water Piping and Trim E Multiple Boiler Installation continued NOTICE Installing a low water cutoff in the system piping of multiple boilers is strongly recommended and may be required by Local Codes ...

Page 63: ... of 2 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 VI Water Piping and Trim E Multiple Boiler Installation continued ...

Page 64: ... of 2 VI Water Piping and Trim E Multiple Boiler Installation continued 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 20 for recommended Boiler Loop Circulator ...

Page 65: ...45 Grundfos UPS 32 80 2 max speed 41B NOTES Note 1 Required Alliance SL Coil Flow Rate exceeds Max Allowable Flow Rate thru Boiler this Boiler Alliance SL combination may result in boiler heat exchanger erosion and noise Note 2 Required Alliance SL Coil Flow Rate is below Min Required Flow Rate thru Boiler this Model can only be installed as separate heating zone off system header see Figure 40A f...

Page 66: ...ded 41B Note 2 SL35 6 9 SL50 6 9 5 SL70 6 10 SL119 14 17 0 27 0 Taco 1400 45 Grundfos UPS 32 80 2 max speed 41B Note 3 ALP399 1 1 2 1 1 2 2 2 37 7 30 2 21 5 SL27 6 9 NA Not Recommended 41B Note 2 SL35 6 9 SL50 6 9 5 SL70 6 10 SL119 14 17 0 NOTES Note 1 Required Alliance SL Coil Flow Rate exceeds Max Allowable Flow Rate thru Boiler this Boiler Alliance SL combination may result in boiler heat excha...

Page 67: ...nch W C Pressure Drop Nominal Pipe Size In Inside Diameter In Length of Pipe Ft 10 20 30 40 50 60 70 80 90 100 0 622 172 118 95 81 72 65 60 56 52 50 0 824 360 247 199 170 151 137 126 117 110 104 1 1 049 678 466 374 320 284 257 237 220 207 195 1 1 380 1392 957 768 657 583 528 486 452 424 400 1 1 610 2085 1433 1151 985 873 791 728 677 635 600 2 2 067 4016 2760 2217 1897 1681 1523 1402 1304 1223 1156...

Page 68: ...049 456 314 252 215 191 173 159 148 139 131 1 1 380 937 644 517 442 392 355 327 304 285 269 1 1 610 1403 964 775 663 588 532 490 456 427 404 2 2 067 2703 1858 1492 1277 1131 1025 943 877 823 778 2 2 469 4308 2961 2377 2035 1803 1634 1503 1399 1312 1239 3 3 068 7615 5234 4203 3597 3188 2889 2658 2472 2320 2191 1 CFH of LP Gas is approximately equal to 2 5 MBH contact your gas supplier for the actua...

Page 69: ...e Do not use gas piping as grounding electrode Refer to National Electrical Code NFPA 70 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 bl...

Page 70: ...s non corrosive leak detector solution D Gas Piping for Multiple Boiler Installation 1 Individual module boiler gas pipe sizing specific details see paragraph A 2 Individual module boiler recommended gas piping detail see Figure 42 3 An additional gas pressure regulator s may need to be to installed to properly regulate inlet gas pressure at the smallest individual module boiler DANGER Do not use ...

Page 71: ...ater temperature exceeds the set point of the limit control Certain Local Codes require an additional water temperature limit In addition certain types of systems may operate at temperatures below the minimum set point of the limit contained in the boiler If this occurs install an additional water temperature limit Honeywell L4006 Aquastat Wire as indicated in the Electrical Section of this manual...

Page 72: ...72 103448 02 6 13 VIII Electrical continued ...

Page 73: ...103448 02 6 13 73 VIII Electrical continued Figure 43 Wiring Connections Diagram ...

Page 74: ...ire the sensor to the boiler using 22 gauge or larger wire VIII Electrical continued Model Number Nominal Current amps ALP080B 2 ALP105B 2 ALP150B 2 ALP210B 3 ALP285B 5 ALP399 5 Table 25 Boiler Current Draw D Power Requirements Nominal boilers current draw is provided in Table 25 These values are for planning purposes only and represent only the boiler s power consumption To obtain total system po...

Page 75: ...103448 02 6 13 75 VIII Electrical continued Figure 44 Ladder Diagram ...

Page 76: ...6 13 Figure 45A Modified Wiring For DHW Priority When Using Low Flow Circulator Piped Off System Header Heating with Central Heating Circulators Plus Alternately Piped Indirect Water Heater VIII Electrical continued ...

Page 77: ...G T STAT POWER SUPPLY 120 60 1 FIELD INSTALLED 40VA TRANSFORMER SEE NOTE 2 WIRE 24V THERMOSTATS W HEAT ANTICIPATOR SET AT 0 9 AMPS 40VA REQ D FOR EVERY 3 ZONE VALVES 2 WIRE 24V THERMOSTATS W HEAT ANTICIPATOR SET AT 0 5 AMPS 40VA REQ D FOR EVERY 4 ZONE VALVES 2 WIRE 24V THERMOSTATS W HEAT ANTICIPATOR SET AT 0 3 AMPS 40VA REQ D FOR EVERY 4 ZONE VALVES WHITE ROGERS 1361 102 ZONE VALVES CHECK FOR CROS...

Page 78: ...78 103448 02 6 13 Figure 46 Multiple Boiler Wiring Diagram Internal Sage2 1 Multiple Boiler Control Sequencer Three Boilers Shown Typical Connections for up to Eight Boilers VIII Electrical continued ...

Page 79: ...between the Tekmar 265 Control and each boiler s Sage2 1 Control The boiler s and system supply water temperature will be reset together to maintain the input that is needed to the system When a call for Indirect Hot Water is generated to the Tekmar 265 the control will de energize the zone pump control ZC terminal energize the Indirect pump and modulate the boiler firing to establish a setpoint t...

Page 80: ...setpoint temperature to supply enough input to the system main to satisfy the desired reset water temperature in the main established by the Tekmar 264 Control When a call for Indirect Hot Water is generated to the Tekmar 264 the control will de energize the zone pump control ZC terminal energize the Indirect pump and sequentially fire the boilers to establish a setpoint temperature in the main fo...

Page 81: ...r installing communications between three or more boilers When two boilers are connected the splitter is not required c Ethernet Cables Ethernet cables are used to connect the boiler network together These are standard straight through cables that can be purchased at electrical distributors Alternately the network can be wired together by simply wiring terminal J3 Modbus 2 terminals A B and V betw...

Page 82: ...ign all boilers a unique Boiler Address using any number from 1 through 8 WARNING When two boiler s addresses are the same undesirable simultaneous operation occurs 5 Enable 1 Boiler Master Enable only one Control s Sequencer Master WARNING When more than one Sequencer Master is enable erratic behavior will result 6 Power Down All Boilers 7 Power Up Master Sequencer Enabled Boiler First 8 Power Up...

Page 83: ...in Btu per cubic foot from gas supplier 2 Alpine gas valves have inlet and outlet pressure taps with built in shut off screw Turn each screw from fully closed position three to four turns counterclockwise to open taps Connect manometers to pressure taps on gas valve NOTICE If it is required to perform a long term pressure test of the hydronic system the boiler should first be isolated to avoid a p...

Page 84: ...84 103448 02 6 13 IX System Start up continued Figure 51 Lighting Instructions Alpine Series Lighting and Operating Instructions ...

Page 85: ...e has been established for the first time subsequent calls for burner operation should result in a flame on the first try I Check Burner Flame Inspect the flame visible through the window On high fire the flame should be stable and mostly blue Figure 52 No yellow tipping should be present however intermittent flecks of yellow and orange in the flame are normal J Check Gas Inlet Pressure Check the ...

Page 86: ...d see Figure 7B Flue sensor port of boiler concentric vent collar floor standing build see Figure 18 Remove Flue Temperature Sensor and insert the analyzer probe through Flue Temperature Sensor silicon cap opening or if required remove also the Flue Temperature Sensor silicon cap and insert the analyzer probe directly into flue sensor port Reinstall the sensor and the cap upon combustion testing c...

Page 87: ...acent to the rating plate Apply the Gas Valve Label to a conspicuous area on the gas valve Apply the Boiler Conversion Label to a conspicuous surface on or adjacent to the outer boiler jacket Fill in the date of the conversion and the name and address of the company making the conversion with a permanent marker 8 Install Flue Temperature Sensor into Flue sensor port of boiler CPVC PVC two pipe ven...

Page 88: ... the boiler being converted 3 If conversion is being made on a new installation install the boiler in accordance with the installation instructions supplied with the boiler If an installed boiler is being converted connect the new gas supply to the boiler check for gas leaks and purge the gas line up to the boiler in accordance with the National Fuel Gas Code ANSI Z223 1 or the requirements of the...

Page 89: ...CO2 will actually increase O2 will drop as the throttle is turned clockwise If the boiler appears to operate with air deficiency turn the throttle clockwise to increase the amount of Excess Air to the burner As the throttle is turned clockwise the CO2 level will rise eventually peaking 11 8 or 13 8 depending of the type of gas being used before falling conversely O2 level will drop to 0 before ris...

Page 90: ... system Refer to Paragraph G Adjusting Parameters Pump Setup Menu for additional information Boiler Pump Domestic Pump 5 Contractor Setup Contractor Name Enter your contact information name address and phone number on this screen In the event of a fault or the need to adjust a setting the display will direct the homeowner to you Address Phone 6 Manual Control Manual Speed Control Use the High and ...

Page 91: ...outsideairtemperatureincreases 6 Warm Weather Shutdown WWSD Some boilers are used primarily for heating buildings and the boilers can be automatically shutdown when the outdoor air temperature is warm When outside air temperature is above the WWSD setpoint this function will shut down the boiler boiler pump and or the system pump 7 Domestic Hot Water Priority DHWP Someboilersareusedprimarilyforbui...

Page 92: ...l automatically adjust downwards as the outdoor temperature increases When the water temperature is properlymatchedtohomeheatingneedsthereisminimal chanceofroomairtemperatureovershoot Excessiveheat is not sent to the room heating elements by overheated supplywatertemperaturemaintainedtoohighasetting water Reset control saves energy by reducing room over heating reducing boiler temperature increasi...

Page 93: ...longer than a limit time delay the Control shuts down the boiler and delays restart If the inverted temperature is detected more than five times the boiler manual reset Hard Lockout is set This condition is the result of incorrectly attaching the supply and return piping 5 External Limit An external limit control can be installed between terminals 11 and 12 on the low voltage terminal strip Be sur...

Page 94: ...Multiple Demands The Sequence Master responds to Central Heat DHW and frost protection demands similar to the stand alone boiler For example when selected and DHW priority is active the sequence master uses DHW setpoint Diff Above Diff Below and pump settings 7 Shared or Isolated DHW Demand When the Indirect Water Heater IWH parameter is set to Primary Piped the Sequence Master sequences all requi...

Page 95: ...present Direct Ignition Spark and Main fuel valve are energized Supply 132 F 140 F Rate 100 Status Setpoint Boiler 1 Priority Central Heat i Running Priority Central Heat Status Running burner On circulator s On After flame is proven normal boiler operation begins Modulation rate depending on temperature and setpoint selections and modulating control action Supply 132 F 180 F Rate 100 Status Setpo...

Page 96: ...ntact Your Qualified Heating Professional Improper settings or service create risk of property damage injury or death Service Contact Adjust Lockout History Service Contract Boiler Size Setup Sequencer Setup Active Faults i Supply 180 F 180 F Rate 0 Status Standby Setpoint Boiler 1 Priority Central Heat i Active Fault 180 F Boiler 1 Energy Save On Max Efficiency On Standby i Status Help Adjust Det...

Page 97: ...1 Priority Central Heat i 2000 800 Boiler Cycles Boiler Cycles Hours i Run Time Hours Pump Status Cycles i System On 98 Boiler On 23 DHW Off 0 Heat Demand i Central Heat On Domestic Hot Water Off Sequence Master Off Frost Protection Off Frost Protection On Exercise On Figure 54 Status Screens Rate The rate value is equal to the actual fan speed divided by the maximum fan speed Setpoint this is the...

Page 98: ...ing parameter status such as On Point Off Point and Setpoint Source information Demand detail screens are provided for Central Heat shown DHW and Sequencer demands Outdoor Reset saves energy and improves home comfort by adjusting boiler water temperature This screenpresentstheactiveresetcurve Thecurveshows the relationship between outside air and outdoor reset setpoint Thecurveshownisadjustablebye...

Page 99: ...e status for boiler address 1 is provided as follows 1 Boiler 1 is connected to the network 1 Blinking underline boiler 1 is starting 1 Solid underline boiler 1 is running Networked Boilers Boiler 1 Lead 50 Firing Boiler 2 50 Firing Boiler 3 0 Available Boiler 4 0 Available i The Networked Boilers screen is selected by pressing the Detail button from the Home screens and pressing Networked Boilers...

Page 100: ... Installer Password required Installer Password 76 Warning Only Qualified Technicians Should Adjust Controls Contact Your Qualified Heating Professional i Press 5 digit display to Input Password Press Save to enter password i 000 1 CL R ES C 5 4 3 2 6 B S 0 9 8 7 Press 5 digit display to Input Password i 076 After inputting the password press to enter password After password is Saved These buttons...

Page 101: ...able Boiler and system circulators start and boiler fires when low outside air supply and return temperatures are sensed as follows 0 Secs 0 900 Secs Anti Short Cycle Time Anti short cycle is a tool that helps prevent excessive cycling resulting from a fast cycling Ther mostat or Zone valves It provides a minimum delay time before the next burner cycle DHW demand is serviced immediately without an...

Page 102: ...Control will go to during a call for heat If the rated input of the installed home radiation is less than the maximum output of the boiler change the Central Heat Maximum Modulation fan speed setting to limit the boiler output accord ingly See Table 32 Minimum to Maximum Modulation Domestic Hot Water DHW Max Modulation This parameter defines the highest modulation rate the Control will go to durin...

Page 103: ...heat off DHW demand Pump Runs during central heat and frost protection call for heat Pump does not start for a DHW call for heat and will be forced off if there is a DHW call for heat and Domestic Hot Water Priority is active Primary Loop Pipe IWH Never Primary Loop Piped IWH Boiler Piped IWH Domestic Pump run pump for Activates the Domestic pump output according to selected function Never Pump is...

Page 104: ...r Boiler Piped Pump Parameter Selections System Pump Central Heat No Priority Never Boiler Pump Central Heat Off DHW Priority Any demand DHW Pump Boiler Piped IWH Never Explanation This piping arrangement does not allow both the boiler and domestic hot water pump to run at the same time When call for Domestic Hot Water is received the DHW pump is turned on and the boiler pump is turned off However...

Page 105: ...s optional It is permissible for the domestic and system pumps to run at the same time The boiler pump must run for every call for heat X Operation G Changing Adjustable Parameters continued Example Pump Parameter selections continued Multiple Boilers IWH piped to primary system pump required to run for any call for heat Sequencer Master Boiler 1 Boiler 2 Wiring locations Thermostat X DHW call for...

Page 106: ...ge mode High Auto Low nOTE Selecting Low or High locks manual mode firing rate at min or max Rate After combustion testing select Auto to return the boiler to normal operation Press Auto to return firing rate to Automatic Mode Press Low to select manual firing rate control and Minimum firing rate Manual Speed Control i Press High to select manual firing rate control and Central Heat Maximum firing...

Page 107: ...ershoots required value increases to high fire causing the temperature to exceed the Diff Above setpoint and cycle the boiler unnecessarily Lower values cause a smaller firing rate change for each degree of temperature change If set too low the firing rate response will be sluggish and temperature will wander away from setpoint Domestic Hot Water X Operation G Changing Adjustable Parameters contin...

Page 108: ... outdoor temperature 70 F 32 F to 100 F High Outdoor Temperature The High Outdoor Temperature parameter is the outdoor temperature at which the Low Boiler Water Temperature is supplied This parameter is typically set to the desired building temperature 110 F 70 F to 190 F Low Boiler Water Temperature The Low Boiler Water Temperature parameter is the operating setpoint when the High Outdoor Tempera...

Page 109: ... 120 140 135 130 125 155 190 160 195 165 185 180 175 170 200 Boost Maximum Off Point Central Heat Setpoint minus Diff Above Low Boiler Water Temp Default 110 F High Outside Air Temp Default 70 F 10 F Hot Water Setpoint Minimum Water Temperature Default 130 F TOD Setback Setpoint Default 170 F Central Heat Setpoint Low Outside Air Temp 180 F 0 F Default Outdoor air reset Setpoint Shown Bold Default...

Page 110: ... to provide heat to the IWH Disabled Enable Disable DHW Two Boiler Start The Sequencer to immediately start two boilers for a DHW call for heat Used when DHW is the largest demand Only visible when primary piped IWH is selected 120 Secs 120 1200 Secs Boiler Start Delay Slave boiler time delay after header temperature has dropped below the setpoint minus Diff below setpoint Longer time delay will p...

Page 111: ...send Theyellowlightshould come on and Limit Open will flash in the Active Faults screen on the display Push the reset button to restore normal operation If yellow light does not come on determine why the low water cutoff is not working properly 2 Follow the procedure for turning the boiler off per Figure 51 Lighting Instructions 3 Inspect the wiring to verify the conductors are in good condition a...

Page 112: ...tor ii Fernox Protector Alphi 11 CH Copal sludge remover corrosion inhibitor Follow manufacturer application procedure for proper heating system boiler cleaning and preventive treatment Above referenced products are available from Cookson Electronics Company 4100 Sixth Avenue Altoona PA 16602 Tel 814 946 1611 and or selected HVAC distributors Contact U S Boiler Company for specific details iii Equ...

Page 113: ...p follow the steps below For parts identification refer to Section XIII Repair Parts 1 Condensate Overflow Switch Removal and Replacement a Disconnect power supply to boiler b Remove two 2 wire nuts and disconnect overflow switch wire pigtails from boiler wiring c Using pliers release spring clip securing the overflowswitchtocondensatetrapbodyandremove theswitch Notethattheswitchhasfactoryapplied ...

Page 114: ...386 e Using pliers release spring clip securing the overflowswitchtocondensatetrapbodyandremove theswitch Notethattheswitchhasfactoryapplied siliconadhesiveseal whichmayhavetobecarefully cut all around to facilitate the switch removal f Usingpliers releasespringclipsecuringcondensate trap body to the heat exchanger bottom drain stab g Firstly pull the trap downwards to release from the heat exchan...

Page 115: ...ng reconnected green light will begin to flash Display Completely Dark but Boiler fires No 5 Vdc Power to Display Loose 5 Vdc connection wiring between display and Control Defective Display or Control 00FF display lost communication with control Loose or defective display harness Defective Display Defective Control ER0011 Adjustment Mode Password Timeout The Control and Display are NOT defective T...

Page 116: ...her open or closed graphically represents each safety limit The closed contact icon is steady the open contact icon is blinking For example the screen shown to the left illustrates a closed Air Pressure Switch contact and an open Auto Reset High Limit contact The Auto Reset High Limit is causing the boiler to stop firing NOTE Since the limit string items are wired in series all limits downstream o...

Page 117: ...es for Hard Lockout 4 Loose wiring to limit device External Limit defective or jumper not installed Low Gas Pressure Switch contact open if installed LWCO switch not installed and jumper missing If yellow light on LWCO is on system is low on water If neither yellow or green light is on check LWCO harness 7 Return sensor fault Shorted or open return temperature sensor Shorted or mis wired return se...

Page 118: ...proving failed Blower is not running at Purge rate when it should or blower speed signal not being detected by Sage2 1 Loose connection in 120 VAC blower wiring Loose or miswired blower speed harness Defective blower 20 Invalid Safety Parameters Unacceptable Sage2 1 control Safety related parameter detected Safety Parameter verification required Contact factory 21 Invalid Modulation Parameter Unac...

Page 119: ...ugh your local U S Boiler Wholesale distributor Should you require assistance in locating a U S Boiler distributor in your area or have questions regarding the availability of U S Boiler products or repair parts please contact U S Boiler Customer Service at 717 481 8400 or Fax 717 481 8408 ...

Page 120: ...120 103448 02 6 13 From Wiring Harness 1G 1H 1F 1C 1E 1A 1D 1B 1G 1H 1F 1C 1E 1A 1D 1B From Wiring Harness 1J 1N 1M 1L 1K XIII Repair Parts continued 1E 1P 1C 1D ...

Page 121: ...01372 03 1N Gasket Header 3 4 NPT N A 101372 01 1P Gas Air Intake Duct Assembly 101725 01 101725 02 1Q Burner Plate Insulation Warning Contains RCF 101728 01 1R Burner Plate Inner Seal 101729 01 1S Burner Plate Outer Seal 101730 01 1T Burner Head 101731 01 101731 02 101731 03 101731 04 101731 05 101731 06 1U Burner Head Seal 101732 01 1V Insulation Disc Warning Contains RCF 101996 01 101996 02 M6x...

Page 122: ...rews Air Intake Adapter Air Connection Side Swirl Plate 2x M5 x 16 mm Phillips flat head screws Blower Adapter Plate Air Intake Adapter Blower Side Spacer Plate for size 080 through 150 only 101704 01 101704 02 101704 03 101704 04 2C Gas Valve 102975 01 102975 02 102975 04 102975 05 102975 06 2D Gas Valve Harness with Plug MCBA Control 102971 02 Sage2 1 Control 102971 01 2E Blower Outlet Gasket 10...

Page 123: ...witch 104425 01 104426 01 4B Air Pressure Switch Tubing Black 7016039 7016041 103473 01 4C Condensate Trap Blow Molded 101239 01 4D Blocked Condensate Drain Switch 101587 01 4E Spring Clip Condensate Trap 2 101632 01 4F Rubber Grommet Condensate Trap 101595 01 4G Condensate Comp Fitting 101546 01 XIII Repair Parts continued ...

Page 124: ...2 080 27 105 02 105 27 150 02 150 27 210 02 210 27 285 07 399 07 150 70 210 70 285 70 5A Sage2 1 Programmed Kit 104472 01 104472 02 104472 03 5B Programmed Display with Mounting Hardware 104427 01 5C Sage2 1 Transformer 102516 01 XIII Repair Parts continued ...

Page 125: ...Assembly Right Side 101232 01 101232 02 101232 03 101232 04 101232 05 101232 06 6G Heat Exchanger Support Left Side 101224 01 101224 02 101224 03 101224 04 101224 05 101224 06 6H Bracket High Voltage Terminal 102780 01 6J Bracket Rear HX Support 101381 01 6K Jacket Support Bracket 2 101593 01 6L Lower Front Door Assembly 101227 01 101227 02 6M Jacket Upper Front Panel 101509 01 6N Bracket Right Cl...

Page 126: ...30 Schedule 40 CPVC Pipe 102193 02 N A 1 7D 3 Schedule 80 CPVC 90 Elbow 102192 01 1 N A 4 Schedule 80 CPVC 90 Elbow 102192 02 N A 1 7E 8 oz Bottle of Transition Cement 102195 01 1 7F 8 oz Bottle of Primer 102194 01 1 7G 3 x 3 CPVC PVC Vent System Connector 102183 01 1 N A 3 x 4 CPVC PVC Vent System Connector 102183 02 N A 1 N A 4 x 4 CPVC PVC Vent System Connector 102183 03 N A 1 7H 3 x 4 CPVC PVC...

Page 127: ...02942 02 102942 03 8A Temperature Pressure Gauge 100282 01 8B External Gas Shut Off Valve 806SOL0005 101615 01 8C Relief Valve 81660363 81660302 8D Boiler Drain Valve 806603061 8E Boiler Stacking Brackets 2 101679 01 8F Boiler Stacking Bracket Screws 8 80860743 Outdoor Temperature Sensor Not Shown 102946 01 102439 01 XIII Repair Parts continued ...

Page 128: ...acket Wall 102869 01 N A 9F Air Collar Plate Assembly 102871 02 102871 01 N A 9G Air Collar Plate Gasket 102876 01 N A 9H Access Panel Rear Air Box 102873 01 N A 9J Horizontal Strip Gasket 2 102875 01 N A 9K Vertical Strip Gasket 2 102874 01 N A 9L Access Panel Gasket 102877 01 N A 1 4 20 x 5 8 Hex Head Cap Screw Not Shown 4 80861312 N A 1 4 20 Hex Nut w Lock Not Shown 4 80860456 N A Sheet Metal S...

Page 129: ...Harness includes 10A 10B 10C 10D 102701 02 10A Main Low Voltage Harness 103009 02 10B High Voltage Harness 103010 02 10C Blower Power Harness 103012 01 10D Communication Harness 103011 01 10E Igniter Harness 103486 01 10F Wiring Harness Thermal Link Burner Door Thermostat N A 104574 01 XIII Repair Parts continued ...

Page 130: ...irator 2 Long sleeved loose fitting clothing 3 Gloves 4 Eye Protection Take steps to assure adequate ventilation Wash all exposed body areas gently with soap and water after contact Wash work clothes separately from other laundry and rinse washing machine after use to avoid contaminating other clothes Discard used RCF components by sealing in an airtight plastic bag RCF and crystalline silica are ...

Page 131: ...ion Air Piping Floor Mounted Boiler Builds Figure 7B 27 Field Installation of CPVC Vent Pipe Wall Mounted Boiler Builds Figure 8 28 Wall Penetration Clearances For PVC Vent Pipe Figure 9A 28 Direct Vent Sidewall Terminations Figure 9B 29 Direct Vent Sidewall Terminations Optional Figure 10 29 Rodent Screen Installation Figure 11 29 Direct Vent Optional Sidewall Snorkel Terminations Figure 12 30 Di...

Page 132: ... 64 Alternate Multiple Boiler Water Piping w Indirect Domestic Hot Water Heater Page 2 of 2 Section VII Gas Piping Figure 42 69 Recommended Gas Piping Section VIII Electrical Figure 43 72 73 Wiring Connections Diagram Figure 44 75 Ladder Diagram Figure 45A 76 Modified Wiring For DHW Priority When Using Low Flow Circulator Piped Off System Header Heating with Central Heating Circulators Plus Altern...

Page 133: ...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 ...

Page 134: ...nations M G DuraVent Table 10 31 Approved Polypropylene Pipe Fittings and Terminations Centrotherm Eco Table 11 33 Polypropylene Vent System and Combustion Air System Components Equivalent Length vs Component Nominal Diameter Table 12 36 Summary of PP Flex Two Pipe Direct Vent System Option Table 13A 37 U S Boiler Company Vent System Components Stainless Steel Table 13B 38 Alternate Vent Systems a...

Page 135: ...l 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 Using the Boiler Type Parameter Selections Section XIII Repair Parts N A Pages 120 thru 129 Appendix B Tables continued ...

Page 136: ...136 103448 02 6 13 U S Boiler Company Inc P O Box 3020 Lancaster PA 17604 1 888 432 8887 www usboiler net ...

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