U.S. Boiler Company ALTA-120 Installation, Operating And Service Instructions Download

Page: 53 / 100

110328-02 - 6/22

ALTA

Installation, Operating & Service Instructions

Operation

Figure 15-1: Display Icons

180

°F

When not flashing or alternating display temperature is

boiler supply temperature.

Visible when Central 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: Display Descriptions

Summary of Contents for ALTA-120

Page 1: ...Works 6 5 Locating Boiler 8 6 Preparing Boiler 12 7 General Venting 15 8 Sidewall Direct Venting 22 9 Vertical Direct Venting 28 10 Heating System Piping 34 11 Gas Piping 41 12 Field Wiring 42 13 Cond...

Page 2: ...rious 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...

Page 3: ...n 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...

Page 4: ...ss deadly gas that may be introduced into your home by any malfunctioning fuel burning product or vent system failure It is strongly recommended that CO alarms be installed near bedrooms and on all le...

Page 5: ...itude 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 We...

Page 6: ...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 p...

Page 7: ...7 110328 02 6 22 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 8: ...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...

Page 9: ...ning 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 i...

Page 10: ...minants 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 ch...

Page 11: ...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...

Page 12: ...to earthquakes may have special requirements that take precedence over requirements in these instructions Unpack Boiler Figure 6 1 What s in the Box Boiler Misc Parts Carton Wall Retaining Clip 2X Wa...

Page 13: ...lled 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 v...

Page 14: ...nd attach bracket using provided 5 16 in x 2 in lag screws and 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 boil...

Page 15: ...tion 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 Terminatio...

Page 16: ...inished vent and air piping to ensure air tightness and compliance with provided instructions and code requirements Do not mix components from different venting systems Covering non metallic vent pipe...

Page 17: ...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 Ve...

Page 18: ...bur 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 Foll...

Page 19: ...h 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...

Page 20: ...ths 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 Boil...

Page 21: ...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...

Page 22: ...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 9...

Page 23: ...23 110328 02 6 22 ALTA Installation Operating Service Instructions 8 Sidewall Direct Venting continued Figure 8 1 Vent Terminal Clearances Air Terminal not Shown for Clarity...

Page 24: ...f 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 o...

Page 25: ...e 7 11 Figure 8 8 Low Profile Terminal Grade or Snow line From boiler vent connection Possible Orientations 12 305mm Min To boiler air connection Gra Sno Possible Orientations To boile air connec Dura...

Page 26: ...G 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 r...

Page 27: ...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 Gra...

Page 28: ...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 locati...

Page 29: ...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 Alterna...

Page 30: ...igure 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...

Page 31: ...t 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 Rou...

Page 32: ...dapter 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...

Page 33: ...t 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...

Page 34: ...mage if valve opens The end of discharge pipe must terminate in unthreaded pipe C If safety relief valve discharge is not piped to drain it must terminate within 6 in 150 mm of floor D Do not route di...

Page 35: ...m Piping continued 4 Expansion tank required A Ifthisboilerisreplacinganexistingboilerwith no other changes in system old expansion tank can generally be reused B If expansion tank must be replaced co...

Page 36: ...local jurisdiction A Protection of this boiler against low water and or inadequate flow is provided by UL353 listed flow switch built into boiler B Thisisawatertubeboilerandthisflowswitch is therefore...

Page 37: ...ER MATERIAL ALTA NEAR BOILER PIPING PRIMARY SECONDARY HEAT ONLY DES E CHK APVD DATE DRAW 09 UNLESS OTHERWISE NOTED ALL DIMENSIONS IN INCHES TOLERANCES X X 1 X XXX 005 X XX 03 ANGLE 1 PROPERTY OF U S B...

Page 38: ...SE ITEM NUMBER MATERIAL ALTA NEAR BOILER PIPING PRIMARY SECONDARY W INDIRECT WATER HEATER DES EJL CHK APVD SCALE 1 15 SIZE B SHEET 1 OF 1 DATE REVISION DRAWING NUMBER 09 13 2021 TS 103 66 A UNLESS OTH...

Page 39: ...ING PRIMARY SECONDARY W HEADER HEAT ONLY DES EJ CHK APVD DATE DRAWI 01 UNLESS OTHERWISE NOTED ALL DIMENSIONS IN INCHES TOLERANCES X X 1 X XXX 005 X XX 03 ANGLE 1 PROPERTY OF U S Boiler Company Inc LAN...

Page 40: ...c LANCASTER PA THIS DOCUMENT CONTAINS CONFIDENTIAL INFORMATION AND ITS CONTENTS ARE THE SOLE PROPERTY OF U S BOILER COMPANY INC ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF...

Page 41: ...SI 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 liq...

Page 42: ...ocations are shown in Figure 12 1 To access terminal strips 1 Remove front door Front door is removed by first loosening two thumb screws located under front of door 2 Disconnect igniter wire at burne...

Page 43: ...Sensor Optional Outdoor Temperature Sensor 1 Outdoor Sensor Optional Outdoor Temperature Sensor 2 Available when Lead Lag Master Enabled Figure 12 2 120 VAC Connections Low Voltage Connections Figure...

Page 44: ...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 electri...

Page 45: ...able 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 cond...

Page 46: ...stem 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 allow...

Page 47: ...g 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 co...

Page 48: ...rode 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 altitu...

Page 49: ...or 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 displa...

Page 50: ...s 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 ev...

Page 51: ...lencher un incendie ou une explosion entra nant 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 b...

Page 52: ...t 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 ioniz...

Page 53: ...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 w...

Page 54: ...ring 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 1...

Page 55: ...1 is latest entry 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 C...

Page 56: ...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 bel...

Page 57: ...n 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 sh...

Page 58: ...tion 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...

Page 59: ...g 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...

Page 60: ...iler 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...

Page 61: ...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 cu...

Page 62: ...ter 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...

Page 63: ...ds 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 Temper...

Page 64: ...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...

Page 65: ...gas inlet pressure tapping Performed combustion test Screw cap in vent adapter No errors or holds present on display Tested additional field installed controls for functionality outlined by manufactur...

Page 66: ...othing 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...

Page 67: ...teps 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 unobstru...

Page 68: ...7 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 result...

Page 69: ...during this inspection and for details on supporting pitching and terminating vent system 12 Inspect hydronic system A Look for leaks and repair if found If system contains antifreeze or other additiv...

Page 70: ...tA 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 disp...

Page 71: ...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...

Page 72: ...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 t...

Page 73: ...Speed Demanded 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 outp...

Page 74: ...lly 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 te...

Page 75: ...essary 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 mu...

Page 76: ...ure 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 Fau...

Page 77: ...ection 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...

Page 78: ...t 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 disp...

Page 79: ...inued 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 ga...

Page 80: ...h 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...

Page 81: ...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...

Page 82: ...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 outp...

Page 83: ...lt 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 st...

Page 84: ...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 O...

Page 85: ...85 110328 02 6 22 ALTA Installation Operating Service Instructions 19 Internal Wiring Diagrams Figure 19 1 Ladder Diagram...

Page 86: ...86 110328 02 6 22 ALTA Installation Operating Service Instructions 19 Internal Wiring Diagrams continued Figure 19 2 Wiring Schematic Diagram...

Page 87: ...87 110328 02 6 22 ALTA Installation Operating Service Instructions Figure 19 2 Wiring Schematic Diagram continued 19 Internal Wiring Diagrams continued...

Page 88: ...Gasket 110880 01 6 7 Burner Door Assembly includes burner ignitor flame sensor gasket and hardware 110575 01 111560 01 8A 8B 8C Ignitor Flame Sensor includes sensor gasket and hardware 111423 01 8B Ig...

Page 89: ...0B 10A 16 11B 12 13 11A 120 MBH 11A 80 150 180 MBH 17 15 14 A A B B 2 1 TITLE FIRST USE ITEM NUMBER MATERIAL ALTA SERVICE PARTS WATER PIPING COMPONENTS DES EJL CHK APVD SCALE 1 5 SIZE A SHEET 1 OF 1 D...

Page 90: ...9 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 110881 01 50 23 52 53 51 24A 24B 24...

Page 91: ...ey No Description Part Number 120 150 180 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 bra...

Page 92: ...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...

Page 93: ...Auto Reset LWCO 105591 01 Manual Reset LWCO 108182 01 Fernox Alphi 11 108862 01 Hydronic System Corrosion and Lime scale Inhibitor 108863 01 Header Sensor 108703 01 Outdoor Temperature Sensor 108681 0...

Page 94: ...ration of cooling system Figure A 1 Isolated Boiler from Refrigeration System Water Chiller Shut off Valves Expansion Tank Circulator Return main from combined heating cooling system Supply main to co...

Page 95: ...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 recomme...

Page 96: ...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...

Page 97: ...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...

Page 98: ...ant 5 min ensuite d terminer si le coupe tirage d borde l ouverture de d charge Utiliser la flamme d une allumette ou d une chandelle ou la fum e d une cigarette d un cigare ou d une pipe 6 Une fois q...

Page 99: ...99 110328 02 6 22 ALTA Installation Operating Service Instructions SERVICE RECORD SERVICE PERFORMED DATE...

Page 100: ...100 110328 02 6 22 ALTA Installation Operating Service Instructions U S Boiler Company Inc P O Box 3020 Lancaster PA 17604 1 888 432 8887 www usboiler net...

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U.S. Boiler Company ALTA-120, Installation, Operating And Service Instructions

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