U.S. Boiler Company ALTA-080 Installation, Operating And Service Instructions Download Page 37

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110328-04 - 2/23

ALTA

Installation, Operating & Service Instructions

Boiler

Model

Boiler Supply

Connection

inch, FPT

Boiler Return

Connection

inch, FPT

ΔT = 35°F

ΔT = 30°F

ΔT = 25°F

ΔT = 20°F

Minimum

Required

Flow

(GPM)

Boiler

Head

Loss,

(Ft.)

Minimum

Required

Flow

(GPM)

Boiler

Head

Loss,

(Ft.)

Minimum

Required

Flow (GPM)

Boiler

Head

Loss,

(Ft.)

Minimum

Required

Flow

(GPM)

Boiler

Head

Loss,

(Ft.)

ALTA-080

4.3

7.2

5.0

9.5

6.0

13.1

7.5

19.8

ALTA-120

ALTA-120B

6.4

11.2

7.5

14.6

9.0

20.0

11.2

29.7

ALTA-150

8.1

8.2

9.4

10.9

11.3

15.3

14.1

23.4

ALTA-180

9.7

11.6

11.3

15.5

13.5

21.8

16.9

33.5

Notes:

1. Required Flow (GPM) = **Output (MBH) x 1,000/(500 x ΔT)

**Output (MBH) - select value for specific boiler model from Table 3-1. Using boiler antifreeze will result in higher pressure drop

and may require larger circulators.

2. Boiler head loss includes 50 eq ft. near boiler piping. [Approximately 20 ft. straight pipe, (4) 90° elbows and (2) full port ball

valves]

Heating System Piping

(continued)

Figure 10-2: System Curve w/ 50 Equivalent ft. of Piping

Summary of Contents for ALTA-080

Page 1: ...5 Locating Boiler 10 6 Preparing Boiler 14 7 General Venting 17 8 Sidewall Direct Venting 24 9 Vertical Direct Venting 30 10 Heating System Piping 36 11 Gas Piping 42 12 Field Wiring 43 13 Condensate Disposal 47 14 Start Up and Checkout 48 15 Operation 55 16 Before Leaving Jobsite 67 17 Service and Maintenance 68 18 Troubleshooting 72 19 Internal Wiring Diagrams 87 20 Service Parts 90 Appendix A C...

Page 2: ...erious injury DANGER Explosion Hazard DO NOT store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance If you smell gas vapors DO NOT try to operate any appliance DO NOT touch any electrical switch or use any phone in the building Immediately call the gas supplier from a remotely located phone Follow the gas supplier s instructions or if the supplier...

Page 3: ...on flue products and fuel contain alumina silica heavy metals carbon monoxide nitrogen oxides and or other toxic or harmful substances that can be hazardous to health and life and that are known to the State of California to cause cancer birth defects and other reproductive harm Do not disconnect pipe fittings on boiler or in heating system without first verifying system is cool and free of pressu...

Page 4: ...eful life Be sure to protect walls carpets and valuables from water that could leak from boiler WARNING Asphyxiation Hazard Fire Hazard A qualified installer service agency or gas supplier should annually inspect boiler including annually inspecting all vent gaskets and replacing any exhibiting damage or deterioration If you are not qualified to install or service boilers do not install or service...

Page 5: ...ickup allowance of 1 15 The manufacturer should be consulted before selecting a boiler for installations having unusual piping and pickup requirements such as intermittent operation extensive piping systems etc 3 For altitudes above 2 000 ft 610 m ALTA 080 minimum input increased to 10 MBH Model Number Depth in mm Width in mm Height in mm Space Heating Water NPT in Gas NPT Maximum Allowable Workin...

Page 6: ... 3 80 2 5 0 76 135 41 1 5 Reduced to 50 eq ft 15 2 m for 150 and 180 boiler LP installation above 8 000 ft 2 438 m Table 3 5 Inlet Gas Pressure Range Min in wc kPa Max in wc kPa Natural Gas 2 5 0 62 14 0 3 48 LP Gas 8 0 1 99 Table 3 4 Altitude De rates 1 000 ft Boiler Model 2 000 to 6 000 ft 611 m to 1 828 m 6 001 to 8 000 ft 1 829 m to 2 438 m 8 001 to 10 100 ft 2 439 m to 3 079 m NG LP NG LP NG ...

Page 7: ...ut for altitude conversion instructions For part no ending in 02 i e ALTA 180 1G02 boiler is listed for 0 to 2 000 ft 610 m Do not install above 2 000 ft 610 m Model Number Shipping Weight lb kg Empty Boiler Weight lb kg Shipping Crate D in mm Shipping Crate W in mm Shipping Crate H in mm Water Content gal L Heat Exchanger Surface Area ft2 m2 ALTA 080 107 49 71 32 41 4 1050 20 0 508 18 3 465 0 5 1...

Page 8: ...e connection board Provides field connections for thermostats external limits remote firing devices 4 20mA or 0 10V header sensor outdoor sensor and LWCO 9 Control enclosure Houses boiler control and provides access to installed fuses and spare fuses 10 Local user display Allows review of boiler status and parameter adjustment In event of fault condition LCD display turns red and fault condition i...

Page 9: ...9 110328 04 2 23 ALTA Installation Operating Service Instructions 4 How It Works continued Figure 4 1 How It Works 1 2 4 3 12 17 13 15 8 7 9 11 14 10 ...

Page 10: ... location Manufacturer will not be held responsible for water damage resulting from this appliance or any of its components 5 Check for and remove any combustible materials gasoline or other flammable liquids from area around boiler 6 Check for and remove any potential combustion air contaminants from area around boiler and area around vent air termination See Table 5 2 WARNING Explosion Hazard Do...

Page 11: ...pening within 12 in 305 mm of floor Minimum free area 100 in 2 650 cm2 for each opening This free area takes into account blocking effect of grills and louvers If using screens minimum screen size 1 4 in 6 4 mm 1 4 6mm 6 150mm 8 1 4 210mm 1 2 13mm 1 2 13mm Provide access to this area for inspection and cleanout of condensate trap Vent Air 1 2 13mm Closet Door 0 12 0 305mm 0 12 0 305mm Closet Door ...

Page 12: ...aminants to avoid Spray cans containing chloro fluorocarbons CFC s Permanent wave solutions Chlorinated waxes cleaners Chlorine based swimming pool chemicals Calcium chloride used for thawing Sodium chloride used for water softening Refrigerant leaks Paint or varnish removers Hydrochloric acid muriatic acid Cements and glues Antistatic fabric softeners used in clothes dryers Chlorine type bleaches...

Page 13: ...n which the appliances remaining connected to the common venting system are located and other spaces of the building Turn on clothes dryers and any appliance not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maxi mum speed Do not operate a summer exhaust fan Close fireplace dampers 4 Place in operation the applianc...

Page 14: ...ft boiler onto wall mounting bracket Ensure wall bracket is anchored to structure capable of supporting weight of boiler and attached piping when filled with water Areas subject to earthquakes may have special requirements that take precedence over requirements in these instructions Unpack Boiler Figure 6 1 What s In The Box What s In The Box service part shown 107160 01 Vent connector 2 in 110882...

Page 15: ...alled vent reducer 3 in to 2 in could cause unreliable operation at elevated carbon monoxide levels resulting in severe personal injury death or substantial property damage 3 Lubricate heat exchanger vent gasket with soapy water 4 Insert vent connector through jacket into heat exchanger with flue gas sample port facing forward See Figure 6 2 5 Tighten 4 screws Install Vent Connector Figure 6 2 Ins...

Page 16: ...washers For wood studs with drywall or paneling greater than 1 2 in 12 mm thick metal studs or masonry wall use anchors suitable for boiler weight and appropriate for wall material 4 Hang boiler on wall bracket See Figure 6 4 5 Attach bottom retaining clips to boiler and mark hole locations Drill 3 16 in 4 8 mm pilot holes C and D and attach to wall using provided 5 16 in x 2 in lag screws or othe...

Page 17: ...ction 8 for details Figure 7 3 Sidewall Concentric Termination see Section 8 for details Direct Vent Sidewall Termination Options Direct Vent Vertical Termination Options Figure 7 4 Vertical Termination with Fittings see Section 9 for details Figure 7 6 Vertical Termination with Abandoned B vent or Chimney Chase see Section 9 for details Figure 7 5 Vertical Concentric Termination see Section 9 for...

Page 18: ...e air tightness and compliance with provided instructions and code requirements Do not mix components from different venting systems Covering non metallic vent pipe and fittings with thermal insulation is prohibited Follow all local codes for isolation of vent pipe when passing through floors or walls Do not use a barometric damper draft hood or vent damper with this boiler Do not connect any othe...

Page 19: ... following or equivalent may be used to join CPVC to PVC A Primer IPS P 70 B Cement IPS 790 Material Standard Vent Pipe CPVC sched 40 or 80 ASTM F441 PVC sched 40 or 80 ASTM D1785 PVC DWV ASTM D2665 Vent Fittings CPVC sched 80 ASTM F439 PVC sched 40 ASTM D2466 PVC sched 80 ASTM D2467 PVC DWV ASTM D2665 Primer Cement CPVC ASTM F493 PVC ASTM D2564 Table 7 11 Listed CPVC PVC Vent Materials 4 Work fro...

Page 20: ...ebur inside and outside of pipe ends after cutting 11 Dry fit all vent and air components before cementing any joints 12 Use field supplied primer and cement appropriate for materials being joined Follow primer and cement instructions to join pipe and fittings 13 Clean all pipe ends and fittings with appropriate primer before cement Apply primer to both pipe and fitting socket before applying ceme...

Page 21: ...th of straight run between anchors X Loop horizontal only top view Y 5 6 150mm Min 6 150mm Min 2Y 5 7 General Venting continued Figure 7 15 CPVC PVC Venting Expansion Loops Figure 7 14 PVC Venting Wall Penetration Clearance Key Hanger allows linear movement Anchor restricts linear movement Can use either anchor or hanger Pipe Dia in X ft m Y in cm 2 20 6 1 41 104 30 9 1 50 127 40 12 2 58 147 50 15...

Page 22: ...gths of elbows and fittings 5 Only cut polypropylene vent pipe as permitted by vent manufacturer and in accordance with their instructions Ensure cut end is square and deburred prior to assembly 6 Boiler vent connector is gasketed Lubricate gasket with soapy water insert pipe until it bottoms out and tighten clamp See Figure 7 18 7 Assemble remainder of vent system in accordance with vent manufact...

Page 23: ... PF LB or 4PF LB Increaser 2 in 60 mm to 3 in 80 mm 2PPS X3L ISIA0203 2PF 2I3 PF LB locking band PVC to PP Adapter 2 in 60 mm 2PPS ADL ISAGL0202 adapter IAFC02 clamp N A Table 7 17 Listed Polypropylene Vent Fittings Vent Clamp PVC to polypropylene adapter required when using polypropylene air piping Joint connector required at all joints in venting system Air Vent Air PVC to polypropylene adapter ...

Page 24: ... as stones or balls or subject to buildup of leaves or dirt 4 Maintain clearances to vent terminal per Figure 8 1 A Minimum 12 in 305 mm from any door window or other gravity air inlet B Minimum 3 ft 900 mm above any forced air inlet located within 10 ft 3 1 m C Minimum 12 in 305 mm from inside corner 6 ft 1 8 m is generally recommended and requiredwhenwindowand orairinletiswithin 4 ft 1 2 m of in...

Page 25: ...25 110328 04 2 23 ALTA Installation Operating Service Instructions 8 Sidewall Direct Venting continued Figure 8 1 Vent Terminal Clearances Air Terminal not Shown for Clarity ...

Page 26: ...If venting with polypropylene i Use UV resistant or UV stabilized components for all exterior pipe and fittings ii Remove gasket from terminal fitting to install screen 6 Brace exterior vertical runs of piping as required 7 Seal exterior openings thoroughly with exterior caulk Figure 8 5 CPVC PVC Fittings Terminal Assembly CPVC PVC or Polypropylene Fittings Terminal WARNING Asphyxiation Hazard All...

Page 27: ...nd fittings listed in Table 7 11 Figure 8 8 Low Profile Terminal DuraVent Selkirk Remove gasket to install screen Elbow Screen Wall Thimble From boiler vent connection To boiler air connection Elbow Joint Connector Table 8 7 CPVC PVC Low Profile Terminal Kits Length Ipex Diversitech 2 in 60 mm 397984 HVENT 2 3 in 80 mm 397985 HVENT 3 3 Follow terminal manufacturer s instructions for assembly NOTIC...

Page 28: ...NG Asphyxiation Hazard If vent system is too short to accommodate required 30 in 760 mm of CPVC pipe and CPVC elbow between boiler and PVC venting use listed CPVC terminal kit Failure to comply could result in severe personal injury death or substantial property damage 2 Required vent pipe and fittings listed in Table 7 11 Table 8 9 CPVC PVC Concentric Terminal Kits Length Ipex Diversitech 2 in 60...

Page 29: ...0 mm 3PPS HKC ICWT352 terminal ICCT3503 two pipe adapter 3PF HCT terminal 3PF CTA two pipe adapter Polypropylene Concentric Sidewall Terminal DuraVent shown From boiler vent connection 12 305mm Min Grade Snow line To boiler air connection C 12 305mm Min B Concentric Wye Fitting Inner Vent Pipe Rain Cap Outer Air Intake Pipe To install stainless steel screw and nut locate drill location dimple on o...

Page 30: ...l arrangement with vertical vent and sidewall air intake is permitted See Figure 9 5 9Vertical Direct Venting WARNING Asphyxiation Hazard Follow these instructions when determining vent terminal location Failure to comply could result in severe personal injury death or substantial property damage 1 Do not exceed maximum equivalent vent and air pipe length in Table 7 7 2 Vent must terminate at leas...

Page 31: ...l Fittings DuraVent PolyPro Centrotherm InnoFlue Selkirk PolyFlue UV resistant single wall pipe 2PPS BG screen UV stabilized end pipe IASPP02 screen UV resistant pipe 2PF HVST screen Figure 9 5 Alternate Vertical Vent Sidewall Air Terminal Normal snow line on roof Elbow with screen Grade Snow Line 10 3 1m 24 610mm Min Air Intake Pipe PVC Coupling or Polypropylene end pipe with screen Fire Stop lis...

Page 32: ...Figure 9 7 for assembly Figure 9 6 CPVC PVC Concentric Terminal 9Vertical Direct Venting continued From boiler vent connection To boiler air connection 12 305mm Min USA 18 460mm Min Canada 24 610mm Max Roof or snow line Figure 9 7 CPVC PVC Concentric Vertical Installation Wye Fitting Clamp or Strap field supplied Roof Line Rain Cap Outer Pipe Inner Pipe Storm collar and Roof Flashing or equivalent...

Page 33: ...rt PVC adapter and install electrical conduit locknut to secure Seal all joints with RTV silicone B DuraVent InstallPolyProlowerB ventadapter in base of tee C Centrotherm Install cap in base of tee Route smooth section of InnoFlue flex throughcapinbaseoftee Usewallplateand RTV silicone to seal this penetration Polypropylene Concentric Terminal WARNING Asphyxiation Hazard All polypropylene vent sys...

Page 34: ...adapter See Text Flex Male Adapter 10 3 1m 24 610mm Min 12 305mm Min Boiler Notes 1 All B Vent joints must be sealed with RTV 2 Seal the Flex Male Adapter to the inside of the lower B Vent Adapter with RTV 3 Seal the Air Intake Pipe to the B Vent Cap with RTV Figure 9 13 Centrotherm Polypropylene B vent Air Chase System Fire Stop listed for use with B Vent PPs Flex B Vent Normal snow line on roof ...

Page 35: ...ct Venting continued Table 9 15 Polypropylene Masonry Chimney Chase Components DuraVent PolyPro Centrotherm InnoFlue Selkirk PolyFlue 2PPS FKC chimney kit 2PPS FLEX flex length IFCK02 chimney kit with flex length 2PF FLEX KIT chimney kit 2PF FLEX length Length 25 35 or 50 ft e g 2PPS FLEX25 for 25 ft length Note 2 in 60 mm components shown Replace 2 with 3 for 3 in 80 mm part numbers Figure 9 16 M...

Page 36: ...Commercial Products 5th edition 10 Heating System Piping 2 Pump required Boiler loop pump is supplied with this boiler and sized for near boiler piping equivalent length of 50 ft See Table 10 1 for flow range through boiler At least one additional pump is required on system side B Pipe outlet of safety relief valve to location where water or steam will not create a hazard or cause property damage ...

Page 37: ...7 5 19 8 ALTA 120 ALTA 120B 1 1 6 4 11 2 7 5 14 6 9 0 20 0 11 2 29 7 ALTA 150 1 1 8 1 8 2 9 4 10 9 11 3 15 3 14 1 23 4 ALTA 180 1 1 9 7 11 6 11 3 15 5 13 5 21 8 16 9 33 5 Notes 1 Required Flow GPM Output MBH x 1 000 500 x ΔT Output MBH select value for specific boiler model from Table 3 1 Using boiler antifreeze will result in higher pressure drop and may require larger circulators 2 Boiler head l...

Page 38: ... LWCO 105591 01 Manual reset LWCO 108182 01 E Install LWCO in supply piping at point prescribed by the local jurisdiction generally at a point above boiler in common header piping F If probe type LWCO is used be certain that it is located at a point in piping from which air can escape to an automatic air vent G Generally this means there should be no down turns in piping between LWCO and point whe...

Page 39: ...A At least eight pipe diameters upstream of first tee B No further apart than 12 305mm or four pipe diameters whichever is smaller Safety Relief Valve System Zone Valves Heating System Circulator Optional Zone Valve Controlled System 10 Heating System Piping continued NOTICE Installer is responsible for piping configurations to provide proper flow rates and meet local codes NOTICE Primary secondar...

Page 40: ...12 305mm or four pipe diameters whichever is smaller Full Port Isolation Valve Indirect Circulator Flow Check Valve Indirect Return Indirect Supply Indiect Domestic Water Heater IWH Safety Relief Valve System Zone Valves Heating System Circulator Optional Zone Valve Controlled System 10 Heating System Piping continued NOTICE Installer is responsible for piping configurations to provide proper flow...

Page 41: ...41 110328 04 2 23 ALTA Installation Operating Service Instructions 10 Heating System Piping continued Figure 10 5 Near Boiler Piping Supplied with Boiler ...

Page 42: ...NSI Z223 1 National Fuel Gas Code and or CAN CSA B149 1 Natural Gas and Propane Installation code Figure 11 1 shows typical gas piping and connection to boiler A Use thread compound compatible with liquefied petroleum gas B Asedimenttrapmustbeinstalledupstreamof gas controls C A manual shut off valve provided in parts carton must be installed within 6 ft 1 8 m of boiler D Support weight of gas pip...

Page 43: ...ny field supplied controls NOTICE Boiler is equipped with a UL 353 listed high water temperature limit This limit provides boiler shutdown in event boiler water temperature exceeds setpoint of control Certain local codes require an additional water temperature limit If necessary install an additional water temperature limit Honeywell L4006 Aquastat Wire as indicated in Figure 12 3 Locating Field C...

Page 44: ...mum recommended current draw for auxiliary pump is 1 5A From left to right connections on terminal strip are Terminal Description Heat T Stat 24 VAC thermostat R 24V Hot Heat T Stat 24 VAC thermostat W Energized on Call for Heat Heat T Stat 24 VAC thermostat C 24V Common Aux T Stat 24 VAC thermostat R 24V Hot Aux T Stat 24 VAC thermostat W Energized on Call for Heat External Limit Field supplied s...

Page 45: ... from sun iv Avoid placing sensor near potential sources of electrical noise such as transformers power lines and fluorescent lighting v Wire sensor to boiler using minimum 22 AWG wire vi Where electrical noise sources cannot be avoided wire sensor using 2 conductor UL Type CM AWM Style 2092 shielded cable Connect one end of shielding on this cable to ground E Header Temperature Sensor Use only Ho...

Page 46: ...46 110328 04 2 23 ALTA Installation Operating Service Instructions 12 Field Wiring continued Figure 12 5 TACO SR504 or Equivalent Zone Panel Wiring Connection Diagram ...

Page 47: ...t P N 101897 01 is available from manufacturer B Do not route or terminate condensate drain line piping through an area that is prone to freezing temperatures or that could be damaged by leaking condensate C If point of condensate disposal is above trap it will be necessary to use a condensate pump to move condensate from boiler to drain Insuchcases selectacondensatepumpthat is listed for use with...

Page 48: ...ystem which could result in property damage Freeze Protection If freeze protection is required see Appendix B for additional information Fill Water System WARNING Burn Hazard Never exceed maximum allowable working pressure on heat exchanger ASME plate 50 psig 345 kPa A 30 psig 207 kPa safety relief valve is included with this boiler 1 Fill system ensuring water quality meets requirements of this m...

Page 49: ...ng to a safe draining location B Turn vent counter clockwise and allow heat exchanger to vent until a steady stream of water is observed C Close vent and remove hose 5 Isolate each zone to purge air confirming that heating system and boiler are completely filled 3 Inspect all wiring for loose uninsulated or miswired connections 4 Verify boiler and system are full of water and pressurized NOTICE Wh...

Page 50: ...electrode shipped with boiler with electrode from conversion kit 111745 01 14 Start Up and Checkout continued High Altitude Conversion WARNING Asphyxiation Hazard Do not attempt to operate boiler at altitude without making proper adjustments to control 1 Change parameter A07 altitude selection according to the following table Control is shipped from factory with A07 default value of 0 Table 14 3 A...

Page 51: ...ror code Figure 14 6 Refer to label on access door and Section 18 Troubleshooting to diagnose error Figure 14 6 Home Screen with Error 14 Start Up and Checkout continued 7 If successful ignition display will show flame icon Figure 14 7 Figure 14 7 Home Screen While Running 8 Boiler will automatically perform a calibration to properly set its air fuel ratio i e O2 or CO2 and CO levels 9 Check inlet...

Page 52: ...is sealed before taking combustion readings C For altitudes 0 to 2 000 ft 0 to 610 m CO should not exceed 200 ppm air free For altitudes above 2 000 ft 610 m CO should not exceed 300 ppm air free In event of high CO see Section 18 Troubleshooting 11 Perform a check of ignition safety shut off device With burner firing carefully unplug black ignitor flame sensor wire at burner door using a pair of ...

Page 53: ...especte pas à la lettre les instructions dans la présente notice risque de déclencher un incendie ou une explosion entraînant des dommages des blessures ou la mort A Cet appareil ne comporte pas de veilleuse Il est muni d un dispositif d allumage qui allume automatiquement le brûleur Ne tentez pas d allumer le brûleur manuellement B AVANT DE FAIRE FONCTIONNER reniflez tout autour de l appareil pou...

Page 54: ...at Status Calibration Burner On Pump s On After burner is started a Calibration is initiated due to 1 Power Cycle 2 Periodic requirement Calibration after blower reaches calibration speed setting ionization setpoint is calibrated next blower drives to low fire and fuel valve output is calibrated runs for 1 minute Priority Central Heat Status Run Burner On Pump s On After burner ignition following ...

Page 55: ...l Heat demand is present Visible when DHW demand is present Icon will flash if DHW setpoint is being adjusted Visible when burner is firing Icon adjacent to active priority Combi boilers only Visible when CH setpoint reset is enabled Visible when adjust mode is active Icon will flash if manual mode is enabled Visible when manual reset lockout is active User Display Overview reset Table 15 2 Displa...

Page 56: ...iring Rate rUn Run Time Hours CYC Boiler Cycles H Hold or Warning Condition E Manual Reset Lockout Not available with local user display The STA status display code contains below listed values Table 15 5 Managing of Status Numbers Display Description see Section 18 Troubleshooting for explanation 0 Self Check 1 Standby 2 Waiting For Air Pressure Switch To Close 3 Prepurge 4 Burner Ignition 5 Cali...

Page 57: ...to B01 and hold reset button until B01 0 Figure 15 7 Adjusting Parameters Menu c c Diagnostic Menu Table 15 9 Diagnostic Menu Display Description C01 Active Detailed Fault Code see Table 18 6 C02 Demand Source 1 Standby 2 Central Heat 1 3 Central Heat 2 4 Domestic Hot Water 5 Sequencer Control 6 CH Frost Protection 7 DHW Frost Protection 8 Boiler On Off Switch 9 Warm Weather Shutdown C03 Fan Speed...

Page 58: ... for 5 seconds enables adjustment by increments of 10 Press enter to accept value password only Pressing menu to exit Navigating Menus Entering password in Adjust Mode allows access to shaded menus below and additional items in Quick Menu Accessing Password Protected Menus Password protected parameters are available by entering a password reset Figure 15 10 Menu Structure or IMPORTANT This boiler ...

Page 59: ...on to LP Gas is required refer to manual Section 14 Startup and Checkout for complete instructions 0 Natural Gas 1 LP Gas 0 0 A07 A07 Altitude Selection visible only after password entered Boiler is shipped from factory configured for sea level 0 to 2 000 ft 0 to 610 Meters 0 0 to 2 000 feet 0 to 610 Meters 1 2 001 to 6 000 ft 611 m to 1 828 m 2 6 001 to 8 000 ft 1 829 m to 2 438 m 3 8 001 to 10 1...

Page 60: ...rate during a CH1 demand Heat T stat input If rated input of installed home radiation is less than maximum output of boiler change F03 setting to limit boiler output accordingly 100 0 100 F04 F04 Central Heat 2 Max Modulation Defines highest modulation rate during a CH2 demand Aux T stat input when selected If rated input of installed home radiation is less than the maximum output of the boiler ch...

Page 61: ...ng this parameter 130 F 54 C 50 F to 180 F 10 C to 83 C 504 504 Central Heat 2 Min Boiler Water Temp Sets a low limit for Reset setpoint Set this parameter to lowest supply water temperature that will provide enough heat for type radiation used to function properly Always consider type of radiation when adjusting this parameter 1 0 1 2 505 505 Auxiliary Thermostat Input Select May be used as Indir...

Page 62: ...oiler Pump Header Sensor Demand Pump runs when boiler is firing and when there is a DHW heat demand Selected when Header Sensor is selected as CH1 and CH2 modulation sensor and boiler is a stand alone boiler 3 Boiler Pump CH Only Off for DHW Pump runs during CH1 CH2 and CH frost protection demand and will be forced off if there is a DHW demand and DHW priority is active This function is selected w...

Page 63: ...r Reset is Enabled boiler will automatically adjust heating zone setpoint temperature based on outdoor reset curve On Enable calculate temperature setpoint based on outdoor temperature using a reset curve defined by Low Outdoor Temp High Outdoor Temp Min Boiler Temp and CH Setpoint and Boost Time parameters Off Disable do not calculate setpoint based on outdoor temperature Table 15 17 Menu 2P 2P Z...

Page 64: ...fter not being used for longer than 7 days This helps prevent pump rotor seizing 7 Pump Air Elimination Pump Purge Pump purge is entered when power is cycled or when there has been an over temperature hold During this state boiler pump cycles on and off every 5 seconds for two minutes to help remove air from boiler water piping This may be interrupted by pressing the reset button 8 Built in Safety...

Page 65: ...eds 63 F 35 C a forced boiler recycle results Boiler will restart automatically once temperature difference has decreased and minimum off time has expired 3 Return Temperature Higher Than Supply Temperature inversion Limit Control monitors supply and return temperature sensors If return water temperature supply water temperature for longer than a limit time delay control shuts down and restarts bo...

Page 66: ... an ignition failure the control retries 2 times and then goes into soft lockout for one hour After a one hour soft lockout control will retry 2 additional times before control activates a manual reset Hard Lockout 15 Operation continued 11 Central Heating System Frost Protection Frost Protection starts boiler and system pump and fires boiler when low outdoor air low supply water are sensed Contro...

Page 67: ...essure tapping Performed combustion test Screw cap in vent adapter No errors or holds present on display clear recent error codes Tested additional field installed controls for functionality outlined by manufacturer i e LWCO high limit or other controls Set proper CH temperature setpoint Set proper DHW temperature setpoint if indirect hot water heater installed Verify system pump operation Adjuste...

Page 68: ...lothing that is sufficiently tight around potential entry points for RCF dust 3 Gloves 4 Eye protection such as goggles safety glasses with side shields or full facepiece Take steps to assure adequate ventilation Handle RCF carefully to minimize airborne dust Use hand tools whenever possible Dampen used RCF with light water spray prior to removal to prevent airborne dust Do not use compressed air ...

Page 69: ...steps are not performed at the intervals specified 1 Inspect vent piping and air intake piping to verify it is free from leakage and deterioration Also verify vent and air intake terminals are unobstructed 2 Inspect condensate drain system to verify it is water tight and unobstructed 3 Inspect water and gas lines to verify they are free from leaks If above inspections reveal potential problems con...

Page 70: ...4 WARNING Asphyxiation Hazard Do not operate boiler without condensate trap ball and ball support in place Doing so could cause products of combustion and or carbon monoxide to enter building resulting in severe personal injury death or substantial property damage Figure 17 3 Ignitor Flame Sensor to Burner Gap 8 Inspect blower gas valve assembly A Look for dust lint or other debris that may have b...

Page 71: ...r additives test and or maintain them as directed by additive manufacturer B Test heating system water quality to ensure they meet minimum requirements specified in Section 14 Start Up and Checkout C Refer to Appendix B for important information on quality and boiler additives 13 Inspect safety relief valve WARNING Explosion Hazard Safety relief valves require periodic maintenance Refer to relief ...

Page 72: ...StA 1 temperature is above setpoint Check temperature setpoint setting Faucet icon is on Servicing DHW demand Boiler is in Warm Weather Shutdown Status StA 14 Feature not available with local user display Boiler Running But System Or Auxiliary Pump Not Running Pump setting is incorrect Switch PU Menu Item P01 System Pump Selection Refer to Table 15 15 Loose wiring to pump Check pump wiring Pump da...

Page 73: ...l fuel gas selection A06 0 for Natural Gas 1 for LP C Control altitude selection A07 for 0 0 to 2 000 ft 0 to 610 m 1 2 001 to 6 000 ft 611 to 1 828 m 2 6 001 to 8 000 ft 1 829 to 2 438 m 3 8 001 to 10 100 ft 2 438 to 3 079 m D Confirm 150 180 LP electrode change brown colored electrode for installations above 2 000 ft 610 m 2 Perform manual calibration 5 times per Table 15 11 A08 3 Follow instruc...

Page 74: ...e overshoot if heating load is too small 7 Rate Limit Firing rate is being limited due to an abnormal condition such as High Supply water temperature High Differential Water temperature High Flue Gas temperature Raised minimum modulation due to loss of flame during run H24 8 Run Modulate Burner is on and is being allowed to freely modulate to match the heating load 9 Postpurge Blower runs for a de...

Page 75: ...Large differences may mean there is a problem with blower C05 3 way valve status 0 DHW 1 CH Combi boilers only C06 System Pump On Off Status Pump status indicate controller 120 VAC output status C07 Boiler Pump On Off Status C08 Auxiliary Pump On Off Status C09 Flame Signal Flame signal strength displayed in internal calibrated units C10 Safety Software Revision Safety software loaded on control C...

Page 76: ...ally after the minimum off time Anti Short Cycle Time 1 1 Urgent calibration cooling delay Urgent calibration demand present waiting for supply temperature to decrease Boiler will start after supply temperature drops below 95 F 35 C Low supply temperature helps to ensure a successful calibration No action is necessary 1 2 Flow switch closed before boiler pump on Boiler start delayed waiting for fl...

Page 77: ...cessary Replace pump if necessary Heating load at time of error below minimum firing rate of boiler Test individual zones and ensure proper zone sizes Header sensor not sensing temperature Boiler is multiple boiler slave or modulating based on header sensor Check header sensor installation Strap on use heat conductive grease and insulate Thermowell ensure inserted fully Check header sensor tempera...

Page 78: ...ture difference between dual elements too high Measure resistance of each thermistor and compare refer to sensor temperature vs resistance Table 18 7 Replace sensor if necessary H11 E11 Flue Sensor Fault Shorted opened or miswired flue temperature sensor Check flue sensor wiring correct wiring if necessary Check flue sensor refer to sensor temperature vs resistance Table 18 7 Replace sensor if nec...

Page 79: ...tion A06 on local display and power is cycled too fast select original fuel to clear alarm before reselecting desired fuel 17 8 BCC is missing has incompatible software revision or is damaged Remove and reconnect BCC and cycle power Press reset button after power has been re established If problem persists replace control or BCC 18Troubleshooting continued Table 18 5 Active Fault Code and Correcti...

Page 80: ...ot available with local user display Check CH 20 mA Water Temperature is greater than CH 4 mA Water Temperature 18 6 Invalid Recirc Comfort Mode configuration Feature not available with local user display Auxiliary thermostat input selection not set to Recirculation Enable 18 7 Factory defaults not turned on Ensure BCC is installed and select A10 factory Default On Table 15 11 18 8 Pump mismatch B...

Page 81: ...tinued Detailed Fault Code found on b and c menus in brackets e g 1 0 Code Name Possible Cause Corrective Action H22 E22 No Flame At Ignition No gas insufficient gas supply pressure Verify no air in gas line Check gas supply pressure Check gas valve inlet pressure during operation Ignition cable not plugged in Connect ignition harness check cable has continuity Fuel Gas Selection parameter A06 or ...

Page 82: ...ch peer to peer boiler has a unique slave address between 1 and 8 30 1 Sequencer slave has lost communication with Sequencer Master master header sensor failure Check boiler to boiler connection wiring Check master is powered and configured Check header sensor wiring or configuration 30 2 Multiple sequencer masters detected Check each boiler Lead Lag Master Enable parameter L01 setup Only one boil...

Page 83: ... contact is closed when it should be open H06 E06 H06 0 Hold Flue gas sensor detected temperatures in excess of 194 F 90 C or when used preferred Stack Flue Limit minus 10 E06 1 Lockout Flue gas sensor detected temperatures in excess of 204 F 96 C or when used preferred Stack Flue Limit H07 E07 H07 1 Hold Return temperature higher than supply temperature E07 0 Lockout Return temperature higher tha...

Page 84: ...5 Warning Invalid Setpoint interpolation parameters H18 6 Hold Invalid Recirc Comfort Mode configuration E18 7 Lockout Selected boiler model default parameters not available H18 8 Hold Boiler pump output parameter set to Disabled or boiler pump output set to Boiler Pump CH Off for DHW and Auxiliary pump outlet is not set to DHW Boiler Piped IWH E19 E19 0 Lockout Air Fuel ratio outside acceptable l...

Page 85: ...ult Missing calibration Calibration not carried out although required Calibration counter reached zero check why calibration management did not work H26 3 Warning Emergency stop The burner had to be stopped during calibration adaption either due to high outlet DHW temperature or a blocking lockout error H27 H27 0 Hold 120 VAC supply voltage less than 73 VAC H28 H28 0 Hold Control 24 VAC wrong freq...

Page 86: ...0 86 30 8056 104 40 5324 122 50 3599 140 60 2483 158 70 1748 176 80 1252 194 90 912 212 100 674 230 110 506 248 120 384 Table 18 8 Outdoor Air Temperature Sensor Temperature versus Resistance 10 kOhm Outdoor Temperature Ohms of Resistance F C 20 28 9 106926 10 23 3 80485 0 17 8 61246 10 12 2 47092 20 6 7 36519 30 1 1 28558 40 4 4 22537 50 10 0 17926 60 15 6 14356 70 21 1 11578 76 24 4 10210 78 25 ...

Page 87: ...87 110328 04 2 23 ALTA Installation Operating Service Instructions 19 Internal Wiring Diagrams Figure 19 1 Ladder Diagram ...

Page 88: ...88 110328 04 2 23 ALTA Installation Operating Service Instructions 19 Internal Wiring Diagrams continued Figure 19 2 Wiring Schematic Diagram ...

Page 89: ...89 110328 04 2 23 ALTA Installation Operating Service Instructions Figure 19 2 Wiring Schematic Diagram continued 19 Internal Wiring Diagrams continued ...

Page 90: ...er Door Gasket 110880 01 6 7 Burner Door Assembly includes burner ignitor flame sensor gasket and hardware 111978 01 110575 01 111970 01 111560 01 8A 8B 8C Ignitor Flame Sensor includes sensor gasket and hardware 111423 01 8B Ignitor Flame Sensor Gasket 106527 01 9 M6 Serrated Flange Hex Nut Obtain locally 1 2A 2B 2C 2D 3A 3B 4 5 6 7 8B 8C 8A 9 All service parts may be obtained through your local ...

Page 91: ...A 10B Water Pipe Gaskets 110577 01 11A 11B Water Pipes w gaskets 111561 01 111562 01 111561 01 12 Return Temp Sensor 106991 01 13 Supply Temp Sensor 106994 01 14 Boiler Pump Grundfos 26 99 Obtain locally 15 T P Gauge 108215 01 16 Boiler Flow Switch O ring 105892 01 17 30 psig 207 kPa Safety Relief Valve 109038 01 10B 10A 16 11B 12 13 11A 120 MBH 11A 80 150 180 MBH 17 15 14 ...

Page 92: ...111571 01 24A 24B 24C 24D 24E 24F 28 29 Gas Valve with gaskets o rings and hardware 111979 01 110587 01 111564 01 25A 25B Air Proving Switch tubing 5 16 in x 13 in long 107862 01 26 47 27 28 29 30 Gas piping with gaskets o rings and hardware 110588 01 28 29 30 50 52 Gas pipe gaskets 110879 01 26 29 Gas adaptor 111422 01 27 28 29 30 49 50 51 52 53 Venturi 111980 01 110881 01 50 23 52 53 51 24A 24B ...

Page 93: ...n Part Number ALTA 080 ALTA 120 ALTA 120B ALTA 150 ALTA 180 31A 31B 31C 31D 31E 31F 31G 31H Condensate Trap 110589 01 32 Front Door 110595 01 33 Vent connector 107160 01 42 Side panel 110725 01 111565 01 45 46 Wall brackets 110882 01 Not shown Thumb screw 106033 01 31E 31D 31C 31A 31F 31G 31H 31B 33 32 42 45 46 ...

Page 94: ...ide boiler serial number 37 Model Key 38 120 VAC Connection Board 110726 01 43 Low Voltage Connection Board 110594 01 48 Fuse 0 5A 5 x 20 mm 250V Slow Blow 111420 01 Fuse 1 0A 5 x 20 mm 250V Slow Blow Fuse 5 0A 5 x 20 mm 250V Slow Blow 34 34 36 37 35 48 5A fuse 1A fuse 5A fuse 43 38 NOTICE When replacing control use boiler control service part Boiler control service part is compatible for all mode...

Page 95: ... scale Inhibitor 108863 01 Header Sensor 108703 01 Outdoor Temperature Sensor 108681 01 Service Kit 111419 01 Floor Stand 111576 01 Noise Attenuator N A 111588 01 Altitude Conversion Kit LP installations above 2 000 ft 610 m N A 111745 01 Primary Secondary Header 111884 01 USB Connect Bluetooth Adapter 111667 01 Service Parts kit expanded 111707 01 Heat Exchanger Cleaning Kit 111705 01 Heat Exchan...

Page 96: ... Residential Hydronic Heating Installation and Design I B R Guide 2 If boiler is connected to heating coils located in air handling units where they may be exposed to refrigerated air boiler piping must be equipped with flow control valves or other automatic means to prevent gravity circulation of boiler water during operation of cooling system Figure A 1 Isolated Boiler from Refrigeration System ...

Page 97: ... if it is not safety relief valvemayopenfrequently resultinginregular additions of make up water D If an automatic fill valve is installed installation of a water meter in fill line is strongly recommended so routine additions of make up water can be detected and their cause corrected 3 Non metallic tubing even if system is tight oxygen can be introduced into system through some types of non metal...

Page 98: ... is installed in a crawl space or an attic the hard wired carbon monoxide detector with alarm and battery back up may be installed on the next adjacent floor level b In the event that the requirements of this subdivision can not be met at the time of completion of installation the owner shall have a period of thirty 30 days to comply with the above requirements provided however that during said th...

Page 99: ...l horizontally vented gas fueled equipment does not provide the parts for venting the flue gases but identifies special venting systems the following requirements shall be satisfied by the manufacturer 1 The referenced special venting system instructions shall be included with the appliance or equipment installation instructions and 2 The special venting systems shall be Product Approved by the Bo...

Page 100: ...5 min ensuite déterminer si le coupe tirage déborde à l ouverture de décharge Utiliser la flamme d une allumette ou d une chandelle ou la fumée d une cigarette d un cigare ou d une pipe 6 Une fois qu il a été déterminé selon la méthode indiquée ci dessus que chaque appareil raccordé au système d évacuation est mis à l air libre de façon adéquate Remettre les portes et les fenêtres les ventilateurs...

Page 101: ...101 110328 04 2 23 ALTA Installation Operating Service Instructions SERVICE RECORD SERVICE PERFORMED DATE ...

Page 102: ...102 110328 04 2 23 ALTA Installation Operating Service Instructions SERVICE RECORD SERVICE PERFORMED DATE ...

Page 103: ...103 110328 04 2 23 ALTA Installation Operating Service Instructions SERVICE RECORD SERVICE PERFORMED DATE ...

Page 104: ...104 110328 04 2 23 ALTA Installation Operating Service Instructions U S Boiler Company LLC P O Box 3020 Lancaster PA 17604 1 888 432 8887 www usboiler net ...

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

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