U.S. Boiler Company ALTAC-200 Installation, Operating And Service Instructions Download | Manualshive

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92

ALTA

Combi Installation, Operating & Service Instructions

110327-04 - 1/22

21

Service Parts

(continued)

Key No.

Description

Part Number

136 Combi

200 Combi

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

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91
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Summary of Contents for ALTAC-200

Page 1: ...ing 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 Field Wir...

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: ...protective equipment when installing servicing or working near this boiler Materials of construction flue products and fuel contain alumina silica heavy metals carbon monoxide nitrogen oxides and or...

Page 4: ...4 ALTA Combi Installation Operating Service Instructions 110327 04 1 22 SERVICE RECORD SERVICE PERFORMED DATE...

Page 5: ...xposure 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 i...

Page 6: ...ing 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 through fixture may be requi...

Page 7: ...for boiler and internal pump current draw of any external pumps connected to boiler Controls Boiler flow switch and integrated manual reset high limit provided with boiler are both UL 353 listed LP Ga...

Page 8: ...ue temperature sensor Used to monitor flue gas 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...

Page 9: ...9 110327 04 1 22 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...

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: ...ening 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...

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: ...oiler 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 sp...

Page 15: ...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 Install...

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: ...Use only CPVC PVC or polypropylene venting systems listed in Tables 7 11 or 7 16 Thoroughly inspect finished vent and air piping to ensure air tightness and compliance with provided instructions and...

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: ...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 p...

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 04 1 22 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: ...able 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 D...

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: ...adequate 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 B...

Page 38: ...Valve Cold Water Fill Air Separator Expansion Tank Low Loss Header Fill Valve Backflow Preventer Safety Relief Valve Dirt Magnetic Filter highly recommended System Pump w Integral Flow Check Valve Sy...

Page 39: ...icable 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 b...

Page 40: ...DHW adapters and boiler Solder connections to DHW adapters before installing gaskets 11 Domestic Water Piping continued Figure 11 2 Standard DHW Piping NOTICE Water filter to prevent scale is strongly...

Page 41: ...o 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 to boiler on cold water li...

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: ...53 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 li...

Page 44: ...ections on terminal strip are Terminal Description Heat T Stat 24VAC thermostat R 24V Hot Heat T Stat 24VAC thermostat W Energized on Call for Heat Heat T Stat 24VAC thermostat C 24V Common Aux T Stat...

Page 45: ...g 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...

Page 46: ...it 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 cond...

Page 47: ...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 48: ...tail A Scale 2 1 Manual Air Vent Confirm 1 4 ID tubing is connected to hose barb Route tubing to a safe place away from controls before opening vent 4 Eliminate air in boiler by bleeding from heat exc...

Page 49: ...isible Press button until A is visible and press enter Press or buttons until A06 is visible and press enter Press or buttons to change 0 to 1 Press menu 3 times to return to display mode 15 Start Up...

Page 50: ...200 ppm air free in event of high CO see Section 19 Troubleshooting 17 Perform a check of ignition safety shut off device With burner firing carefully unplug black ignitor flame sensor wire at burner...

Page 51: ...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 automatiquement l...

Page 52: ...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 53: ...ntral 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 DHW Comfor...

Page 54: ...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 55: ...ut Hold History Menu Figure 16 7 Adjusting 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...

Page 56: ...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 57: ...5 Central 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...

Page 58: ...est modulation 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 136 com...

Page 59: ...pply water temperature that will provide enough heat for type radiation used to function properly Always consider type of radiation when adjusting this parameter 0 0 1 2 505 505 Auxiliary Thermostat I...

Page 60: ...1 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...

Page 61: ...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 62: ...ng 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 wiring is required Boost featur...

Page 63: ...o 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 maxim...

Page 64: ...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 65: ...pressure Closed 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 outlin...

Page 66: ...clothing 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 adequa...

Page 67: ...owing 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 u...

Page 68: ...ge shown in Figure 18 3 and Table 18 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 carbo...

Page 69: ...oors windows decks etc E Refer to Sections 7 thru 9 to re assemble any vent system components that are disassembled during this inspection and for details on supporting pitching and terminating vent s...

Page 70: ...necter C Initiate a call for heat and confirm that boiler shows an Active Fault H05 indicating flow switch is open WARNING Component Damage If burner comes on with no flow through boiler there is a pr...

Page 71: ...icon is on Servicing DHW demand Boiler is in Warm Weather Shutdown Status StA 14 Feature not available with local user display No Central Heat Boiler Runs 3 way valve defective Check 3 way valve repla...

Page 72: ...flame sensor Refer to Section 18 Service and Maintenance for proper procedure to check ignitor flame sensor Check spark gap and ignitor flame sensor distance to burner Replace if necessary Relief Val...

Page 73: ...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 74: ...Fan Speed Demanded 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...

Page 75: ...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 76: ...is unpowered in DHW Powered in CH If stuck in between disassemble valve and clear any debris Confirm operator is driving fully to powered position Heating load at time of error below minimum firing ra...

Page 77: ...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 78: ...d altitude selection If fuel 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 softwa...

Page 79: ...play Check CH 20 mA Water Temperature is greater than CH 4 mA Water Temperature 18 6 Invalid Comfort Mode configuration Feature not available with local user display Comfort mode selected and Header R...

Page 80: ...kets 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 p...

Page 81: ...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 82: ...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 83: ...F H18 5 Warning Invalid Setpoint interpolation parameters H18 6 Hold Invalid comfort mode configuration E18 7 Lockout Selected boiler model default parameters not available H18 8 Hold Boiler pump outp...

Page 84: ...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 b...

Page 85: ...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 86: ...bottom panel 3 1 2 RD BK BK YE WH WH GND Screw bottom panel L N L N L N L N 120V Line Boiler Pump System Pump Aux Pump R Heat T stat W C R W Aux T stat Ext Limit 0 10V 4 20mA Header Sensor Outdoor Se...

Page 87: ...ch requirements follow The National Electric Code NFPA 70 and or CSA C22 1 Electrical Code Do not provide over current protection greater than 15 Amperes 3 Plugs P1 P2 are shown in line on PCB s for c...

Page 88: ...2 1 P1 1 X1 6 X1 7 X2 3 X1 1 Chassis Ground X1 2 Ignitor Flame Rod Combustion Blower DC Conn Spark DC Tach PWM DC HT 1 X3 1 X3 2 X3 3 X3 4 V2 V2 V1 V1 X3 5 X3 6 X3 7 X3 8 Supply Sensor Return Sensor F...

Page 89: ...oor 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 8...

Page 90: ...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 110581 01 19 3...

Page 91: ...1 25A 25B Air Proving Switch tubing 5 16 in x 12 in long 107862 01 26 47 27 28 29 30 Gas piping with gaskets o rings and hardware 110588 01 23B 23D 28 29 30 Gas pipe gaskets 110879 01 26 29 Gas adapto...

Page 92: ...y No Description Part Number 136 Combi 200 Combi 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 W...

Page 93: ...r 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 20mm 250V Slow Blow 111420 01 Fuse 1 0A 5 x 20mm 250V Slow Blow Fuse 5 0A...

Page 94: ...to 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 scale Inhibitor 108863 01 Header Sensor 108...

Page 95: ...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 96: ...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 97: ...nt 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 requiremen...

Page 98: ...all 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 manufactu...

Page 99: ...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 100: ...100 ALTA Combi Installation Operating Service Instructions 110327 04 1 22 U S Boiler Company Inc P O Box 3020 Lancaster PA 17604 1 888 432 8887 www usboiler net...

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