U.S. Boiler Company ALTA ALTAC-136B Installation, Operating And Service Instructions Download

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110327-07 - 2/23

ALTA

Combi Installation, Operating & Service Instructions

How It Works

(continued)

Figure 4-1: How it works

Summary of Contents for ALTA ALTAC-136B

Page 1: ...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 Domestic Water Piping 39 12 Gas Piping 42 13 Fiel...

Page 2: ...serious 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 a...

Page 3: ...erials of construction 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...

Page 4: ...posure Do not block air flow into or around boiler Insufficient air may cause the boiler to produce carbon monoxide or start a fire BURN HOT Water temperature over 125 F 52 C can cause severe burns in...

Page 5: ...ions having unusual piping and pickup requirements such as intermittent operation extensive piping systems etc 4 Min DHW flow rate required through boiler to initiate DHW demand Higher flow rate throu...

Page 6: ...s and is field convertible to LP gas See Section 15 Start up and Checkout for instructions to convert to LP gas Altitude Only part no ending in 00 i e ALTAC 200 1G00 is listed for 0 to 10 100 ft 3 079...

Page 7: ...ons 3 Specifications continued Safety Relief Valve Vent Connector Air Intake Front View 120 VAC Knockouts Low Voltage Knockouts Domestic Cold Water Inlet Boiler Return Condensate Trap Cleanout Condens...

Page 8: ...exiting boiler Boiler control will alarm reduce boiler firing rate and shut down boiler if flue gas temperature is too high 12 Boiler supply temperature sensor UL 353 Listed Dual element temperature s...

Page 9: ...9 110327 07 2 23 ALTA Combi Installation Operating Service Instructions 4 How It Works continued Figure 4 1 How it works 1 2 4 15 7 8 3 18 12 9 17 13 20 21 22 19 16 11 14 10 23...

Page 10: ...table drain 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 othe...

Page 11: ...opening 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...

Page 12: ...ntaminants 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...

Page 13: ...in 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 syst...

Page 14: ...f 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 Wha...

Page 15: ...ent 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 Inst...

Page 16: ...centers or a masonry wall For other stud spacing mount bracket to 3 4 in 19 mm plywood or horizontal 2 x 4 anchored to studs CAUTION Heavy Object Do not mount boiler to a hollow wall Boiler must be an...

Page 17: ...Section 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 Termina...

Page 18: ...ure 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 insulat...

Page 19: ...he 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...

Page 20: ...de 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 F...

Page 21: ...ngth 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 W...

Page 22: ...engths 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 B...

Page 23: ...03 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 Polypropyl...

Page 24: ...ch 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 f...

Page 25: ...25 110327 07 2 23 ALTA Combi Installation Operating Service Instructions 8 Sidewall Direct Venting continued Figure 8 1 Vent Terminal Clearances Air Terminal not Shown for Clarity...

Page 26: ...B 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 run...

Page 27: ...n Elbow Screen Wall Thimble From boiler vent connection To boiler air connection Elbow Joint Connector 1 Low profile terminals listed in Table 8 7 may be used to terminate air and vent outside buildin...

Page 28: ...NING 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 coul...

Page 29: ...80 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...

Page 30: ...nal 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 loc...

Page 31: ...nal 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 Alte...

Page 32: ...d 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...

Page 33: ...sert 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...

Page 34: ...d 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 w...

Page 35: ...rect 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 wi...

Page 36: ...y of Commercial Products 5th edition 10 Heating System Piping 2 WARNING Burn Hazard Safety relief valve discharge piping must be piped near floor to eliminate potential of severe burns Do not pipe in...

Page 37: ...nadequate flow is provided by UL353 listed flow switch built into boiler B Thisisawatertubeboilerandthisflowswitch is therefore only effective way to provide such protection C Section HG614 c of ASME...

Page 38: ...other means CAUTION Component Damage Excessive heat from soldering could damage gaskets at connection between low loss header and boiler Solder connections to low loss header before installing gasket...

Page 39: ...able codes 2 Flow limiter If DHW draw rate is in excess of rating in Table 3 1 temperature of hot water may be too low for comfortable use Internal 6 GPM 23 L min flow limiter is factory installed but...

Page 40: ...eat exchanger A Cold Water Supply Hot Water To Fixtures Expansion Tank Req d if cold water supply has check valve Drain Valve Drain Valve DHW Pressure Relief Valve ASSE 1017 or ASSE 1070 Listed Temper...

Page 41: ...onnect recirculation pump to Aux Pump terminals per Figure 13 2 Connect jumper time of day clock or momentary push button to Aux T Stat terminals per Figure 13 3 Secure recirculation temp sensor close...

Page 42: ...ANSI Z223 1 National Fuel Gas Code and or CAN CSA B149 1 Natural Gas and Propane Installation code Figure 12 1 shows typical gas piping and connection to boiler A Use thread compound compatible with...

Page 43: ...listed high water temperature limit This limit provides boiler shutdown in event boiler water temperature exceeds set point of control Certain local codes require an additional water temperature limi...

Page 44: ...tions 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 Sta...

Page 45: ...r 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...

Page 46: ...46 ALTA Combi Installation Operating Service Instructions 110327 07 2 23 13 Field Wiring continued Figure 13 5 TACO SR504 or Equivalent Zone Panel Wiring Connection Diagram...

Page 47: ...kit 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 con...

Page 48: ...d oils lubricants These could attack seals in both boiler and system which could result in property damage Freeze Protection If freeze protection is required see Appendix B for additional information...

Page 49: ...ening vent 4 Eliminate air in boiler by bleeding from heat exchanger manual air vent on top left side of heat exchanger Figure 15 1 A Use 1 4 in 6 mm ID tubing connected to hose barb and route tubing...

Page 50: ...1 Press and hold menu for 3 seconds Press or buttons until PAS is visible and press enter Press enter button while PA1 is visible Press or buttons until password 86 is reachedandpress enter Pressandho...

Page 51: ...nition sequence This soft lockout can be reset by interrupting power to boiler 5 Once a flame has been established for first time subsequent calls for burner operation should result in a flame on firs...

Page 52: ...screw cap in vent adapter Be sure to replace this cap when combustion testing is complete B Measure carbon monoxide CO level after 5 minutes of operation above 50 firing rate Thiscanbedonebyproviding...

Page 53: ...ce risque de d clencher 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 auto...

Page 54: ...Calibration Burner On Pump s On Three Way Valve CH After burner is started a Calibration is initiated due to 1 Power Cycle 2 Periodic requirement Calibration after blower reaches calibration speed se...

Page 55: ...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 Visible when Recirculation C...

Page 56: ...r Temperature Fr Demanded Firing 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...

Page 57: ...Parameters Menu c c Diagnostic Menu Table 16 9 Diagnostic Menu Display Description C01 Active Detailed Fault Code see Table 19 6 C02 Demand Source 1 Standby 2 Central Heat 1 3 Central Heat 2 4 Domesti...

Page 58: ...ld 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...

Page 59: ...Heat 2 Setpoint Desired water temperature of CH2 0 0 1 A06 A06 Fuel Gas Selection visible only after password entered Boiler is shipped from factory configured for natural gas Conversion to LP Gas req...

Page 60: ...alled home radiation is less than maximum output of boiler change F03 setting to limit boiler output accordingly 136 combi B 88 200 combi 75 136 combi B 0 88 200 combi 0 75 F04 F04 Central Heat 2 Max...

Page 61: ...water temperature that will provide enough heat for type radiation used to function properly Always consider type of radiation when adjusting this parameter 2 0 1 2 505 505 Auxiliary Thermostat Input...

Page 62: ...nd 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 an...

Page 63: ...lled and Lead Lag Outdoor Reset is Enabled boiler will automatically adjust heating zone set point temperature based on outdoor reset curve On Enable calculate temperature setpoint based on outdoor te...

Page 64: ...l system monitors recent firing rate and burner cycle data to infer current building heat loss Target supply water temperature is then adjusted to match this heat load No outdoor sensor mounting or wi...

Page 65: ...any demands 2 High Differential Temperature Limit Control monitors temperature difference between return and supply sensors If this difference exceeds 58 F 32 C control begins to reduce blower maximu...

Page 66: ...ands when periodic calibration is required and boiler is cold 10 Ignition Failure Control monitors ignition using a burner mounted flame sensor In event of an ignition failure the control retries 2 ti...

Page 67: ...sed gas inlet pressure 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 functio...

Page 68: ...tly 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 c...

Page 69: ...er plates enclosures and guards must be in place when boiler is left in operation NOTICE Warranty does not cover boiler damage or malfunction if the following steps are not performed at the intervals...

Page 70: ...Ignitor Flame Sensor Spark Gap 16 4mm 19 5mm Gap 7 Inspect ignitor flame sensor A Clean off any deposits found with steel wool Do not use sand paper or Emory cloth for this cleaning B Inspect ceramic...

Page 71: ...tight B All supports are intact and vent system is properly pitched C All pipe is in good condition Look for damage such as cracks heat distortion and embrittlement If any such damage is found pipe m...

Page 72: ...controls and components are operating properly before placing boiler back in service 12 Inspect hydronic system and DHW piping A Look for leaks and repair if found If system contains antifreeze or ot...

Page 73: ...5A Fuse supplies power to thermostats Check T0 5 A Fuse replace with a 0 5 Amp 250V Slow Blow 5x20 mm if necessary Boiler Not Responding to Call For Heat Icon is On Boiler is in standby Status StA 1...

Page 74: ...ack flush if necessary Replace if back flushing does not improve performance Recirculation Comfort Mode is used and Recirculation Pump is not On Recirculation pump is turned Off when calibration is re...

Page 75: ...ol 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...

Page 76: ...mperature 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 F...

Page 77: ...ed Large differences may mean there is a problem with blower C05 3 way Valve Status 0 DHW 1 CH 3 way valve and pump status indicate controller 120 VAC output status C06 System Pump On Off Status C07 B...

Page 78: ...cally 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...

Page 79: ...semble valve and clear any debris Confirm operator is driving fully to powered position Heating load at time of error below minimum firing rate of boiler Test individual zones and ensure proper zone s...

Page 80: ...nsor if necessary H10 DHW Sensor Fault Shorted opened or miswired DHW temperature sensor Check DHW sensor wiring correct wiring if necessary Check DHW sensor refer to sensor temperature vs resistance...

Page 81: ...selection 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 Rem...

Page 82: ...eck 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 Recirc Comfort Mode selected and H...

Page 83: ...ntinued 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...

Page 84: ...each 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 wir...

Page 85: ...d 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 exces...

Page 86: ...8 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 o...

Page 87: ...Fault 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...

Page 88: ...10000 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 19 8 Outdoor Air Temperature Sensor Temperature versus Resistance 10 k...

Page 89: ...89 110327 07 2 23 ALTA Combi Installation Operating Service Instructions 20 Internal Wiring Diagrams Figure 20 1 Ladder Diagram...

Page 90: ...90 ALTA Combi Installation Operating Service Instructions 110327 07 2 23 20 Internal Wiring Diagrams continued Figure 20 2 Wiring Schematic Diagram...

Page 91: ...91 110327 07 2 23 ALTA Combi Installation Operating Service Instructions 20 Internal Wiring Diagrams continued Figure 20 2 Wiring Schematic Diagram continued...

Page 92: ...r Door Gasket 110880 01 6 7 Burner Door Assembly includes burner ignitor flame sensor gasket and hardware 110575 01 111970 01 111560 01 8A 8B 8C Ignitor Flame Sensor includes sensor gasket and hardwar...

Page 93: ...110579 01 13 Supply Temp Sensor 106994 01 14 Pump 110580 01 15 T P Gauge 108215 01 16 Boiler Flow Switch O ring 105892 01 17 30 psig 207 kPa Safety Relief Valve 108680 01 18 Plate Heat Exchanger 11058...

Page 94: ...86 01 111571 01 24A 24B 24C 24D 24E 24F 28 29 Gas Valve with gaskets o rings and hardware 110587 01 111564 01 25A 25B Air Proving Switch tubing 5 16 in x 12 in long 107862 01 26 27 28 29 30 47 Gas pip...

Page 95: ...Description Part Number ALTAC 136 ALTAC 136B ALTAC 200 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 4...

Page 96: ...oiler 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...

Page 97: ...02 Condensate Neutralizer Kit 101867 01 Auto Reset LWCO 105591 01 Manual Reset LWCO 108182 01 Tempering Valve 70 145F ASSE 1017 108042 01 Fernox Alphi 11 108862 01 Hydronic System Corrosion and Lime s...

Page 98: ...lt Residential Hydronic Heating Installation and Design I B R Guide Water Chiller Shut off Valves Expansion Tank Circulator Shut off Valves Supply main to combined heating cooling system Return main f...

Page 99: ...on 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 reco...

Page 100: ...ent 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 requireme...

Page 101: ...wall 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 manufact...

Page 102: ...endant 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 foi...

Page 103: ...103 110327 07 2 23 ALTA Combi Installation Operating Service Instructions SERVICE RECORD SERVICE PERFORMED DATE...

Page 104: ...104 ALTA Combi Installation Operating Service Instructions 110327 07 2 23 U S Boiler Company LLC P O Box 3020 Lancaster PA 17604 1 888 432 8887 www usboiler net...

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