U.S. Boiler Company Alpine ALP080B Installation, Operating And Service Instructions Download

Page: 1 / 148

103448-10 - 6/18

Price - $5.00

9700609

Installation, Operating and Service Instructions for



Condensing



High Efficiency



Direct Vent



Gas-Fired



Water Boiler

ALPINE

Residential

As an ENERGY STAR

Partner, U.S. Boiler

Company has determined that the ALPINE

™

Series meets the ENERGY STAR

guidelines for

energy efficiency established by the United States

Environmental Protection Agency (EPA).

TO THE INSTALLER:

Affix these instructions adjacent to boiler.

TO THE CONSUMER:

Retain these instructions for future reference.

Models:

08 MBH through 285 MBH

Improper installation, adjustment, alteration, service or maintenance can cause property

damage, injury, or loss of life. For assistance or additional information, consult a qualified installer,
service agency or the gas supplier. This boiler requires a special venting system. Read these instructions
carefully before installing.

WARNING

Summary of Contents for Alpine ALP080B

Page 1: ...ted States Environmental Protection Agency EPA TO THE INSTALLER Affix these instructions adjacent to boiler TO THE CONSUMER Retain these instructions for future reference Models 08 MBH through 285 MBH...

Page 2: ...res this product to be installed by a Licensed Plumber or Gas Fitter The following terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to impo...

Page 3: ...rior of the building at a minimum height of eight 8 ft above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall...

Page 4: ...Piping and Trim 54 VII Gas Piping 70 VIII Electrical 74 IX System Start up 88 X Operation 96 A Overview 96 B Supply Water Temperature Regulation 97 C Boiler Protection Features 98 D Multiple Boiler Co...

Page 5: ...185 C Inch mm 7 5 16 186 14 1 8 358 D Inch mm 9 5 16 237 10 3 4 273 16 7 16 417 17 1 8 435 18 456 E Inch mm 5 15 16 151 12 1 4 312 Gas Inlet F FPT 1 2 3 4 Return G FPT 1 1 1 4 Supply H FPT 1 1 1 4 Con...

Page 6: ...6 103448 10 6 18 Figure 1A Models ALP080B through ALP210B Floor Mounted I Product Description Specifications and Dimensional Data continued...

Page 7: ...103448 10 6 18 7 Figure 1B Models ALP080B through ALP210B Wall or Floor Mounted I Product Description Specifications and Dimensional Data continued...

Page 8: ...8 103448 10 6 18 Figure 1C Model ALP285B Floor Mounted I Product Description Specifications and Dimensional Data continued...

Page 9: ...tallation at sea level and elevations up to 7800 ft For elevations above 7800 ft the boiler will naturally derate by 1 8 for each 1000 ft above sea level 1 Net AHRI Water Ratings based on piping and p...

Page 10: ...orocarbons paint removers cleaning solvents and detergents Avoid areas containing saw dust loose insulation fibers dry wall dust etc G General 1 Alpine boilers are intended for installations in an are...

Page 11: ...elbow in order to provide adequate space at boiler rear for installation of vent and air intake piping and service access Boiler Service Clearances Applicable to all Boiler Models Top 24 in 610 mm Fro...

Page 12: ...The kit contains Wall Mounting Bracket Bottom Securing Bracket 4 5 16 x 2 long hex head lag screws 4 5 16 flat plated washers and 2 8 x Phillips round head sheet metal screws c 5 16 in x 2 in lag scre...

Page 13: ...5 16 x 2 in lag screws are used TOP EDGE OF BOILER HOLE C HOLE A HOLE D LEFT SIDE OF BOILER 1 0 MIN CLEARANCE TO COMBUSTIBLE 10 0 MIN CLEARANCE TO COMBUSTIBLES 16 253 4 WALL MOUNTING BRACKET CENTER L...

Page 14: ...round slots in the Bottom Securing Bracket Secure the Bracket to the wall using the 5 16 in x 2 in lag screws and 5 16 in plated washers or other fasteners as appropriate Figure 2D l Verify that the f...

Page 15: ...Bracket Placement c Alpine boiler left and right side panels have a series of dimples at panel top and bottom These dimples are positioning dimples for Stacking Boiler Attachment Bracket mounting scr...

Page 16: ...g and Trim for each individual boiler trim installation d Electrical Follow instructions in Section VIII Electrical of the manual to wire individual boilers For side wall venting individual model vent...

Page 17: ...ent Severe boiler corrosion and failure will result Use outdoor air for combustion Do not obtain combustion air from within the building Use specified vent and combustion air pipe diameters Do not red...

Page 18: ...ion air pipe total length of straight pipe plus equivalent length of fittings Table 6A lists equivalent lengths for fittings Do not include vent combustion air terminals in equivalent feet calculation...

Page 19: ...ck intake c Locate bottom of vent and combustion air terminals at least 12 in 300 mm 18 in 460 mm in Canada above the normal snow line and at least 12 in 300 mm above grade level d Locate vent and com...

Page 20: ...creen 5 6A 6B 8 9A 9B 9C 9D A C Vent Horizontal Sidewall UV Resistant Straight Pipe w Screen 11 Intake Horizontal Sidewall UV Resistant 90 Elbow w Screen 6C Vent Vertical Roof UV Resistant Straight Pi...

Page 21: ...installer provided 3 x 2 CPVC concentric reducing coupling or 3 x 2 PVC concentric reducing coupling as applicable see paragraph 6 Horizontal Sidewall Termination and Figure 12 Wall Penetration Clear...

Page 22: ...length of flexible polypropylene liner is 48 ft 14 6 m Asphyxiation Hazard Failure to follow these instructions could cause products of combustion to enter the building resulting in severe property d...

Page 23: ...Direct Vent Vent and Air Intake Horizontal Sidewall Terminations Figure 6B Direct Vent Snorkel Vent and Air Intake Horizontal Sidewall Terminations Figure 6A Direct Vent Staggered Vent and Air Intake...

Page 24: ...lation of DiversiTech HVENT Terminal thru Sidewall PITCH INTAKE AWAY FROM BOILER IF POSSIBLE 3 PVC AIR INTAKE PIPE CPVC VENT PIPE FIRST 30 ELBOW PVC VENT PIPE PITCH VENT PIPE 1 4 PER FOOT TOWARDS BOIL...

Page 25: ...continued Figure 6J Installation of IPEX FGV or DiversiTech CVENT Concentric Terminal thru Sidewall Figure 6H Cutting IPEX FGV or DiversiTech CVENT Concentric Terminal Figure 7A Direct Vent Vent and...

Page 26: ...B CPVC PVC Venting continued Figure 7B Direct Vent Vertical Two Pipe Venting Air Intake with IPEX FGV or DiversiTech CVENT Concentric Terminal Figure 7C Installation of IPEX FGV or DiversiTech CVENT C...

Page 27: ...om roof surface Allow additional vertical X distance for expected snow accumulation Figure 9 Field Installation of CPVC PVC Two Pipe Vent Connector with Factory Installed Flue Temperature Sensor and S...

Page 28: ...on of CPVC Vent Pipe Wall Mounted Boiler Builds Figure 11 CPVC PVC Expansion Loop and Offset Table 6A Expansion Loop Lengths Nominal Pipe Dia In Length of Straight Run Ft Loop Length L In 2 20 44 30 5...

Page 29: ...ent Screen 102191 02 N A N A N A N A 2 3 x 30 Schedule 40 CPVC Pipe 102193 01 1 N A 1 N A N A 4 x 30 Schedule 40 CPVC Pipe 102193 02 N A N A N A N A 1 3 Schedule 80 CPVC 90o Elbow 102192 01 1 N A 1 N...

Page 30: ...tal Termination Description Ipex Part Number Applicable to Boiler Models 2 Low Profile Termination Kit 196894 ALP080B ALP105B 3 Low Profile Termination Kit 196895 ALP150B ALP210B 4 Low Profile Termina...

Page 31: ...p and operate properly The installation is not complete unless the harness and the sensor are interconnected 3 Near Boiler Vent Combustion Air Piping Refer to Figure 10A and the following Steps a Mode...

Page 32: ...ed 3 x 2 concentric PVC reducing coupling onto the end of PVC ASTM 2665 pipe mounted over air box intake collar Thereafter the balance of air intake pipe up to air intake termination can be done with...

Page 33: ...vent pipe Apply sealant between vent pipe and wall opening to provide weather tight seal Sealant should not restrain the expansion of the vent pipe Install contractor provided optional trim plate on w...

Page 34: ...framed walls The fire stop must close the opening between the vent pipe and the structure Whenever possible install vent straight through the roof Refer to Figures 7 and 8 Size roof opening to maintai...

Page 35: ...ustion air system length Use only vent and combustion air terminals and terminal locations shown in 3 Vent Combustion Air Terminals under A General Guidelines of this section C Polypropylene Venting W...

Page 36: ...IV Venting C Polypropylene Venting continued Figure 16A Flexible PP Vent in UNUSED Masonry Chimney with Separate Combustion Air Intake Venting of Other Appliances or Fireplace into Chase or Adjacent...

Page 37: ...Venting C Polypropylene Venting continued Figure 16B Flexible PP Vent in UNUSED B vent with Separate Combustion Air Intake Figure 16C Flexible M G DuraVent PP Vent in UNUSED B vent with Integrated Co...

Page 38: ...Manufacturers Make Model M G DuraVent PolyPro Single Wall Rigid Vent PolyPro Flex Flexible Vent ALP080B through ALP285B Centrotherm Eco Systems InnoFlue SW Rigid Vent Flex Flexible Vent ALP080B throug...

Page 39: ...ations M G DuraVent Boiler Model Centrotherm Eco Part Numbers Sizes Nominal Pipe Diameter CPVC Coupling Adapter PVC to PP Wall Mounted Boiler Builds Male Boiler Adapter PVC to PP Floor Mounted Boiler...

Page 40: ...NA 2ZDCPVCG4 NA 2ZDLC4 2ZDE487UV 2ZDES4 2ZDP4 UV 2ZDES4 NA 2ZDFK4 25 35 NA Note Pipe Length Table 9C Approved Polypropylene Pipe Fittings and Terminations Z Flex Z Dens Boiler Model Selkirk Polyflue P...

Page 41: ...builds have a factory installed vent connector 90 elbow inside air box and air box top located combustion air collar Wall hung boilers having 3 vent connection 90 elbow inside air box ALP080 ALP105 A...

Page 42: ...bly Only cut vent pipe as permitted by the vent manufacturer in accordance with their instructions When pipe is cut cut end must be square and carefully de burred prior to assembly Use locking band cl...

Page 43: ...D for details of B Vent chase M G DuraVent or Centrotherm flexible vent with integrated air intake installation c Refer to Z Flex Z Dens and Selkirk Polyflue catalogs for component selection to addres...

Page 44: ...ting D Stainless Steel Venting continued Figure 17 Field Installation of Two Pipe Vent System Adapter for Stainless Steel Figure 17A Flexible Stainless Steel Vent in UNUSED Masonry Chimney with Separa...

Page 45: ...U 100182 01 2 Vertical Drain Tee 8116304U 100183 01 7 Single Wall Thimble 8116116 100184 01 N A Table 10A U S Boiler Company Vent System Components Stainless Steel Manufacturer Vent System Nominal Dia...

Page 46: ...ess steel adapter into two pipe vent system connector vent or combustion air supply port until bottomed out See Figure 17 d Tighten the worm band clamp screw to secure PVC to stainless steel adapter e...

Page 47: ...w in the downright position Elbow should protrude the same distance from the wall as the exhaust terminal as shown in Figure 5 Install a rodent screen not supplied in the inlet terminal Use a screen h...

Page 48: ...bustion product venting it must be installed at vertical or near vertical plane This will insure proper condensate flow back towards the boiler d Follow flexible stainless steel pipe liner manufacture...

Page 49: ...e en marche les s cheuses tous les appareils non raccord s au syst me d vacuation commun et tous les ventilateurs d extraction comme les hottes de cuisini re et les ventilateurs des salles de bain S a...

Page 50: ...ration may be made g For vertical roof terminations maintain at least 12 in 300 mm minimum horizontal distance between adjacent individual boiler vent terminations 2 Combustion Air Piping a Multiple b...

Page 51: ...103448 10 6 18 51 Figure 18 Multiple Boiler Direct Vent and Air Intake Terminations IV Venting F Multiple Boiler Installation Venting continued...

Page 52: ...es 1A 1B 1C and 19 5 Condensate trap must be filled up with water prior to boiler start up and before connecting any condensate line to the boiler to insure combustion products cannot escape from oper...

Page 53: ...must be performed A pH test or acid test kits are available from HVAC plumbing distributors and should be used to measure condensate acidity before after neutralizer thus indicating a need for servic...

Page 54: ...ft side front in tapping making sure tee run outlets are in vertical plane and parallel to boiler side c Mount in MPT x in FPT Pressure Relief Valve into the tee top outlet d Install Drain Valve into...

Page 55: ...boiler remain within the limits shown in Table 14 any time the boiler is firing 1 Near boiler piping must isolate ALP boiler from system piping via closely spaced tees to insure specified flow range...

Page 56: ...ping amount and number of fittings in the system If system is zoned the system flow rate may drop well below recommended minimum flow when only a single zone is calling for heat 80 105 150 210 285 0 2...

Page 57: ...080B through ALP285B Optional 50 PSI 80 PSI and 100 PSI maximum working pressure rated relief valves are available If the valve is to be replaced the replacement valve must have a relief capacity equa...

Page 58: ...e high limit in the boiler supply piping just above the boiler with no intervening valves Set the manual reset high limit to 200 F Wire the limit per Figures 27 and 28 in Section VIII Electrical 7 Flo...

Page 59: ...tight Do not connect the boiler to radiant tubing without an oxygen barrier Using automatic water refill is not recommended however if such refill is employed awatermetermustbeaddedtoevaluatethemakeu...

Page 60: ...Piping and Trim continued It is the installers responsibility to select pumps and boiler piping configurations that provide the proper flow rates and performance for the boiler and indirect water hea...

Page 61: ...er VI Water Piping and Trim continued It is the installers responsibility to select pumps and boiler piping configurations that provide the proper flow rates and performance for the boiler and indirec...

Page 62: ...ALP285B 2 3 3 3 4 4 5 D Special Situation Installation Requirements Observe the following guidelines when making the actual installation of the boiler piping for special situations 1 Systems containin...

Page 63: ...B a When Alliance SL model coil flow rate required to achieve water heater rating falls within the specified flow range for Alpine boiler model the Alliance SL model can be piped as part of Alpine nea...

Page 64: ...nd Trim continued Figure 24A Multiple Boiler Water Piping w Domestic Hot Water Heater Page 1 of 2 NOTICE Installing a low water cutoff in the system piping of multiple boilers is strongly recommended...

Page 65: ...le Boiler Water Piping w Domestic Hot Water Heater Page 2 of 2 VI Water Piping and Trim continued NOTICE Installing a low water cutoff in the system piping of multiple boilers is strongly recommended...

Page 66: ...Heater Page 1 of 2 VI Water Piping and Trim continued It is the installers responsibility to select pumps and boiler piping configurations that provide the proper flow rates and performance for the b...

Page 67: ...om side of boiler to vertical run of pipe 14 max below top of boiler 14 MAX 12 MAX DHW Circulator Swing Check Valve Indirect Domestic Water Heater IHW Optional Full Port Isolation Valve Full Port Isol...

Page 68: ...SL119 14 17 36 Taco 1400 45 Grundfos UPS 32 80 2 max speed 25B NOTES Note 1 RequiredAllianceSLCoilFlowRateexceedsMaxAllowableFlowRatethroughBoiler thisBoiler AllianceSLcombinationmayresultinboilerheat...

Page 69: ...ALP285B 1 1 4 1 1 4 1 1 2 1 1 2 26 5 21 2 15 1 SL27 6 9 NA Not Recommended 25B Note 2 SL35 6 9 SL50 6 9 5 SL70 6 10 SL119 14 17 0 27 0 Taco 1400 45 Grundfos UPS 32 80 2 max speed 25B Note 3 NOTES Note...

Page 70: ...3 1402 1304 1223 1156 2 2 469 6401 4400 3533 3024 2680 2428 2234 2078 1950 1842 3 3 068 11316 7778 6246 5345 4738 4293 3949 3674 3447 3256 1 CFH of Natural Gas is approximately equal to 1 MBH contact...

Page 71: ...456 314 252 215 191 173 159 148 139 131 1 1 380 937 644 517 442 392 355 327 304 285 269 1 1 610 1403 964 775 663 588 532 490 456 427 404 2 2 067 2703 1858 1492 1277 1131 1025 943 877 823 778 2 2 469 4...

Page 72: ...0 87 1 30 0 68 0 85 0 81 1 40 0 66 B Connect boiler gas valve to gas supply system WARNING Explosion Hazard Failure to use proper thread compounds on all gas connectors may result in leaks of flammabl...

Page 73: ...additional gas pressure regulator is required Using one additional regulator for multiple boilers may result in unsafe boiler operation The additional regulator must be able to properly regulate gas p...

Page 74: ...reduces the boiler water temperature as the heating load decreases This boiler is not used for any space heating This boiler is part of a modular or multiple boiler system having a total input of 300...

Page 75: ...ible to avoid such noise sources wire the sensor using a 2 conductor UL Type CM VIII Electrical continued AWM Style 2092 300 Volt 60 C shielded cable Connect one end of the shielding on this cable to...

Page 76: ...76 103448 10 6 18 VIII Electrical continued...

Page 77: ...103448 10 6 18 77 VIII Electrical continued Figure 27 Wiring Connection Diagram...

Page 78: ...78 103448 10 6 18 Figure 28 Ladder Diagram VIII Electrical continued...

Page 79: ...79 Figure 29A Modified Wiring For DHW Priority When Using Low Flow Circulator Piped Off System Header Heating with Central Heating Circulators Plus Alternately Piped Indirect Water Heater VIII Electr...

Page 80: ...80 103448 10 6 18 Figure 29B DHW Priority Circulators with Zone Panel Piped Off System Header Wiring Schematic for Heating Zone Circulators VIII Electrical continued...

Page 81: ...103448 10 6 18 81 VIII Electrical continued Figure 29C Multiple Boiler Wiring Diagram Internal Sage2 X Multiple Boiler Control Sequencer Three Boilers Shown Typical Connections for up to Eight Boilers...

Page 82: ...82 103448 10 6 18 VIII Electrical continued Figure 29D Boiler to Boiler Communication with Zone Panel...

Page 83: ...83 VIII Electrical continued Figure 30 Modified Wiring For DHW Priority When Using Low Flow Circulator Piped Off System Header Heating with Central Heating Zone Valves Plus Alternately Piped Indirect...

Page 84: ...etween the Tekmar 265 Control and each boiler s Sage2 X Control The boiler s and system supply water temperature will be reset together to maintain the input that is needed to the system When a call f...

Page 85: ...etpoint temperature to supply enough input to the system main to satisfy the desired reset water temperature in the main established by the Tekmar 264 Control When a call for Indirect Hot Water is gen...

Page 86: ...ed on the common system piping and provides blended temperature information to the Sequence Master Refer to piping diagram Figure 24A on page 64 for installation location and Figure 32 or 33 for insta...

Page 87: ...from 1 through 8 WARNING When two boiler s addresses are the same undesirable simultaneous operation occurs 5 Enable 1 Boiler Master Enable only one Control s Sequencer Master WARNING When more than o...

Page 88: ...ructions see Figure 35 After the boiler is powered up it should go through sequence of operation shown in Table 28 on page 100 H Purge Air From Gas Train Upon initial start up the gas train will be fi...

Page 89: ...103448 10 6 18 89 IX System Start up continued Figure 35 Operating Instructions Alpine Series Lighting and Operating Instructions...

Page 90: ...his state is entered when a delay is needed before allowing the burner control to be available and for sensor errors Standby Boiler is not firing There is no call for heat or there is a call for heat...

Page 91: ...n elapsed time for 2 revolutions Boiler Model Altitude Range 0 7000 Ft CO2 O2 Range CO PPM ALP080B 11 4 9 5 High Fire 11 4 9 1 Low Fire 3 5 6 5 High Fire 3 5 7 0 Low Fire Less than 100 PPM ALP105B ALP...

Page 92: ...ss TEST button to simulate low water condition Amber LOW WATER LED should illuminate and burner should turn off b McDonnell Miller 751 Manual Reset LWCO 80160718 Press TEST button for 30 seconds to ac...

Page 93: ...g the converted boiler both on and off 7 A label sheet is provided with the boiler for conversions from natural gas to LP gas Once conversion is completed apply labels as follows a Apply the Rating Pl...

Page 94: ...Throttle Screw Adjustment Values from Fully Closed Position LP Gas Boiler Model Throttle Position Number of Counter clockwise Turns from Fully Closed Position ALP080B 4 ALP105B 4 1 4 ALP150B 5 ALP210B...

Page 95: ...stem Refer to Paragraph F Adjusting Parameters Pump Setup Menu for additional information Boiler Pump Domestic Pump 5 Contractor Setup Contractor Name Enter your contact information name address and p...

Page 96: ...Control TheControlincludessafetycontrolsdesignedtoensure safe and reliable operation In addition to flame safety controlstheControlincludessupplywatertemperature differential water temperature and st...

Page 97: ...outdoor temperature sensor is connected to the boiler and Outdoor Reset is enabled the Central Heat and Auxiliary Heat setpoints will automatically adjusted downwards as the outdoor temperature increa...

Page 98: ...device condensate level switch ThermalLink ALP285Bonly BurnerDoorThermostat with manual reset ALP285B only and external limit optional If any of these limits open the boiler will shut down and an indi...

Page 99: ...eboiler withthewiredDHWdemand and pump fires to satisfy the DHW setpoint 8 DHW Two boiler Start When the Indirect Water Heater IWH parameter is set to Primary Piped and the DHW Two Boiler Start parame...

Page 100: ...unning Priority Central Heat Status Running burner On circulator s On After flame is proven the sequence continues with run stabilization and low fire hold time Once the field adjustable low fire hold...

Page 101: ...ow energy saving flue gas condensation Menu Buttons The Home Screen Menu Buttons connect the displays four main display groups Information Symbol Information symbol links most screens to screen conten...

Page 102: ...dden by the purge light off and low fire hold requirements When a rate limit is the result of boiler protection logic the 6 symbol blinks and becomes a screen link Rate The rate value is equal to the...

Page 103: ...presents measured values for easy comparison Included on this screen is firing rate and when the Zone Panel is connected the measure Heat Loss Measured heat loss is the heat rate kbtu hr sum of all ac...

Page 104: ...underscore Press the zone control button to view individual zone Zone Panel 1 typical for 2 through 4 Zone panel screens show individual zone status cycle counts and individual zone heat loss size in...

Page 105: ...start and last to stop The lead boiler is automatically rotated after 24 hours of run time Additionally the lead is rotated if there is a lead boiler fault Firing Rate Demanded firing rate is provided...

Page 106: ...the Adjust button on the Home screen Press the Adjust button on the Adjust Mode screen or Press Service Contact for service provider contact information Press Login button to access password screen Pr...

Page 107: ...rol s measurement matching the reference reading Not Connected Connected Not Connected Zone Control Status Connected When the Zone Control is connected adjustable settings are automatically shown unde...

Page 108: ...rate at 0 F 18 C combustion air Contact factory before attempting to increase the Maximum Modulation Rate Press Modulation Setup button to access the following parameters Factory Setting Range Choice...

Page 109: ...irst uses the expected heat rate value to set a maximum heat rate The maximum heat rate is the highest heat rate that the boiler can fire to at that moment The maximum heat rate is the summation of th...

Page 110: ...um Expected Heat Rate This parameter defines the highest modulation rate the Control will go to during the auxiliary heat call for heat If the rated input of the Auxiliary Heat Zones is less than the...

Page 111: ...e 12 Pump Runs during central heat and frost protection call for heat Pump does not start for a DHW call for heat and will be forced off if there is a DHW call for heat and Domestic Hot Water Priority...

Page 112: ...at X System pump X DHW pump X Boiler Pump X X Sequencer Master Parameter Selections Sequencer Master Enabled Indirect Water Heater Boiler Piped Pump Parameter Selections System Pump Central Heat No Pr...

Page 113: ...optional It is permissible for the domestic and system pumps to run at the same time The boiler pump must run for every call for heat X Operation F Changing Adjustable Parameters continued Example Pu...

Page 114: ...creen without Saving Clear Entire Field Backspace Save Field and Exit Save Press box to input contractor information Contractor Name i Bill Smith 1 7 6 5 4 3 2 A ES C D C B 8 CL R 7 BS 8 Enter Contrac...

Page 115: ...ter temperature drops Diff Below degrees below the setpoint 3 1 to 5 Response Speed This parameter adjusts the Central Heat temperature controller Proportion Integral Derivative PID values Higher valu...

Page 116: ...equired value increases to high fire causing the temperature to exceed the Diff Above setpoint and cycle the boiler unnecessarily Lower values cause a smaller firing rate change for each degree of tem...

Page 117: ...rate change for each degree of temperature change If set too low the firing rate response will be sluggish and temperature will wander away from setpoint 10 seconds 0 to 300 seconds Low Fire Hold Tim...

Page 118: ...on It is typically set to the coldest outdoor temperature 70 F 21 1 C 32 F to 100 F 0 C to 37 8 C Central Heat High Outdoor Temperature The High Outdoor Temperature parameter is the outdoor tempera tu...

Page 119: ...C Auxiliary Heat Low Outdoor Temperature The Low Outdoor Temperature parameter is also called Outdoor Design Temperature This parameter is the outdoor temperature used in the heat loss calculation It...

Page 120: ...t Type Central Heat Setpoint Heating Element Type 180 F to 190 F 82 2 C to 87 8 C Fan Coil 100 F to 140 F 37 8 C to 60 C In Slab Radiant High Mass Radiant 160 F to 190 F 71 1 C to 87 8 C Convection Ba...

Page 121: ...has dropped below the setpoint minus Diff below setpoint Longer time delay will prevent nuisance starts due to short temperature swings 195 F 90 6 C Central Heat Setpoint 195 F 90 6 C Stop All Boilers...

Page 122: ...and Description Central Heat 1 User defined Zone Control 1 Zone 1 Central Heat 2 User defined Zone Control 1 Zone 2 Central Heat 3 User defined Zone Control 1 Zone 3 Central Heat 4 User defined Zone C...

Page 123: ...two parameters may be used to adjust the signal range Modbus Modbus is used as the temperature setpoint 130 F 54 4 C 80 F 26 7 C Central Heat Setpoint Central Heat 4 20mAdc Setup 4 mA Water Temperatur...

Page 124: ...espirator 2 Long sleeved loose fitting clothing 3 Gloves 4 Eye Protection Take steps to assure adequate ventilation Wash all exposed body areas gently with soap and water after contact Wash work cloth...

Page 125: ...ropriate safeguards and alarms should be installed on the heating system to prevent damage if the boiler is inoperative Burn Hazard This boiler contains very hot water under high pressure Do not unscr...

Page 126: ...and attached securely XI Service and Maintenance continued NOTICE Warranty does not cover boiler damage or malfunction if the following steps are not performed at the intervals specified NOTICE Water...

Page 127: ...with kit Figure 46 Igniter Electrode Gap 3 Remove the igniter assembly and flame sensor and inspect them for oxide deposits Clean the oxide deposits from the igniter electrodes and flame sensor rod w...

Page 128: ...stems iv Sentinel X300 System Cleaner For New Heating Systems v Sentinel X100 Inhibitor For Protecting Closed Loop Hydronic Heating Systems Against Lime scale And Corrosion Follow manufacturer applica...

Page 129: ...and verify the switch operation 2 CondensateTrap Removal and Reinstallation a Disconnect power supply to boiler b Remove 2 wire nuts and disconnect overflow switch wire pigtails from boiler wiring Out...

Page 130: ...eat exchanger Second pull the trap end fromleftsidejacketpanelsealinggrommetand remove the trap from boiler h To reinstall the trap reverse above steps i If the original condensate overflow switch is...

Page 131: ...Defective Control ER0011 Adjustment Mode Password Timeout The Control and Display are NOT defective The password has timed out Simply cycle power to the Display to restore operation ER0012 Control Fa...

Page 132: ...abled Master s Boiler has been powered down To clear fault restore communication or cycle power Boiler Size Setup Boiler Size Fault WARNING Boiler size setting may not match actual boiler size The Boi...

Page 133: ...or reduced to help avoid a lockout or save energy Refer to Hard Lockout section for corrective actions High Stack Temperature Limit High Supply Temperature Limit High Differential Temperature Limit T...

Page 134: ...ce External Limit defective or jumper not installed If yellow light on LWCO is on system is low on water If neither yellow or green light is on check LWCO harness 7 Return sensor fault Shorted or open...

Page 135: ...sure inlet pressure is below maximum on rating plate before replacing valve 18 Light off rate proving failed Blower is not running at Light off rate when it should or blower speed signal not being det...

Page 136: ...ributor Should you require assistance in locating a U S Boiler distributor in your area or have questions regarding the availability of U S Boiler products or repair parts please contact U S Boiler Cu...

Page 137: ...n includes gasket and Molykot 111 grease 104500 01 104501 01 Burner Components N A Replacement Burner Kit Not Shown includes burner head burner head seal and hardware 105188 01 105188 02 105188 03 105...

Page 138: ...Side Swirl Plate 2x M5 x 16 mm Phillips flat head screws Blower Adapter Plate Air Intake Adapter Blower Side Spacer Plate for size 080 through 150 only 101704 01 101704 02 101704 03 101704 04 2B 1 Blo...

Page 139: ...1 3B Replacement Condensate Float Switch Kit 105005 01 3C Spring Clip Condensate Trap 2 per boiler 101632 01 3D Rubber Grommet Condensate Trap 101595 01 3G Air Pressure Switch 104425 01 104426 01 3H A...

Page 140: ...105 02 105 27 150 02 150 27 210 02 210 27 285 07 150 70 210 70 285 70 5A Sage2 X Programmed Repair Kit 106191 01 106191 02 106191 03 5B Programmed Display Repair Kit with Mounting Hardware 106217 04...

Page 141: ...831 04 102831 05 6E Replacement Top Panel Kit includes labels 105181 01 105181 02 105181 03 105181 04 105181 05 6F High Voltage Terminal Bracket 102780 01 6G Replacement Front Door Kit includes labels...

Page 142: ...A 3 Schedule 40 PVC 90 Elbow Air Intake Terminal 106678 01 N A 1 N A 4 Schedule 40 PVC 90 Elbow Air Intake Terminal 106679 01 N A 1 7D 2 3 Schedule 80 CPVC 90 Elbow 102192 01 N A 1 N A 4 Schedule 80 C...

Page 143: ...A Alternate Safety Relief Valve Not Shown 50 PSI 103837 01 N A Alternate Safety Relief Valve Kit Not Shown includes safety relief valve and temperature pressure gauge 80 PSI 104200 01 100 PSI 104201...

Page 144: ...Plate Gasket 102876 01 N A 9H Access Panel Rear Air Box 102873 01 N A 9J Horizontal Strip Gasket Two 2 pcs per assembly required 102875 01 N A 9K Vertical Strip Gasket Two 2 pcs per assembly required...

Page 145: ...ess includes 10A 10B 10C 10D 102701 03 10A Main Low Voltage Harness 103009 03 10B High Voltage Harness 103010 02 10C Blower Power Harness 103012 01 10D Communication Harness 103011 01 10E Igniter Harn...

Page 146: ...146 103448 10 6 18...

Page 147: ...103448 10 6 18 147...

Page 148: ...148 103448 10 6 18 U S Boiler Company Inc P O Box 3020 Lancaster PA 17604 1 888 432 8887 www usboiler net...

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