phc January 2022 www.phcppros.com
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firing again in a matter of minutes. The test lab was impressive. Multiple boilers were being tested and put through their paces. One room was dedicated to testing electronics and controls. In addition to the Alta, one other boiler in particular caught my attention: a new gas-fired steam boiler. See the sidebar for my thoughts on the new SteamMax boiler. Next was the warehouse where boilers and products were stacked floor to ceiling waiting to ship out to supply houses nationwide. Also, in one corner there were test boilers that had been field-tested and removed, waiting to be torn down and inspected by U.S. Boiler's engineering staff. We then ventured down the street to the manufacturing facility. This is the same building I visited a dozen years ago. Gavin Samson, manufacturing process engineer conducted the tour. Lots of changes had been made since my last visit. Cast iron was still manufactured there, but condensing lines have taken over an increasing footprint in this facility. I was impressed by the streamlined manufacturing process. I spoke to several of the line workers. Each station was well laid out and organized to maximize efficiency. I liked the fact that each boiler was test-fired and checked before it was packaged and shipped. The day of my visit, the manufacturing plant was running at maximum capacity to ensure sufficient product availability when the cold weather hits.
More on Alta
The Alta is U.S. Boiler's new combi boiler. It is a gas-fired 95 percent AFUE water-tube boiler with integral space heat as well as DHW. It can provide a solid 3.7 GPM domestic hot water with a 70*F temperature rise. It features a 316L stainless steel heat exchanger and a 10:1 turndown pre-mix burner. It fires at 120 MBH input for heating and 136 MBH input for DHW demand. An additional 180 MBH Heating/200 DHW combi model, plus heating-only models will be introduced in February 2022. A wall-mount bracket and a primary-secondary are included with this boiler for fast, easy installation. Venting is through a sidewall or roof with CPVC or polypropylene. A flexible chimney chase kit is suitable as well. The warranty is exceptional: 5-year warranty on all parts with a 12-year limited warranty on the stainless-steel heat exchanger. The DHW component is compatible with re-circulation. A re-circ pump relay is built into the control. This feature minimizes the wait time for domestic hot water at the fixtures. The Alta features a virtually instantaneous DHW response time as well as tight temperature control resulting in stable DHW supply temperatures under all demand conditions. The biggest innovation is the control system for this boiler. It features an automatic "no touch" combustion management system that continuously monitors the burner and fuel/air mixture and automatically adjusts for safe, clean combustion. The burner self-corrects using flame ionization technology. No manual adjustments are required. It is self-calibrating and adjusts to variations in fuel, air, venting and component wear. It can be converted to LP fuel with a simple switch setting. No LP kit is required. A sensor-less reset control is integral. No hard-wired sensor is required. The control monitors supply and return temperature and adjusts the boiler operation for maximum comfort and efficiency. A "boost" function is built in to the control to ensure the boiler maintains comfort level under all operating conditions. It also features three inputs (two demand and one configurable) as well as three pump relay outputs simplifying control and pump wiring. A boiler flow safety switch is built into the boiler. The Alta control is compatible with a Bluetooth accessory for connection to smartphones. At the time of my visit, a smartphone app was in development for release in the near future. Technicians on site will be able to read, assess and easily adjust the control parameters on their phones. Boiler installation remote monitoring is also planned. Imagine being able to see boiler parameters and error codes remotely, before sending a tech.
Alta installed
My company recently had a chance to test out the Alta on one of our job sites. We have been working on a project in McLean, Virginia, incorporating a 6,000-square foot main house and an 800-square foot detached pool house with a sunroom, garage and in-law suite. This is where the Alta was a perfect fit for the pool house feeding in- slab radiant floor heat. As this is a combi boiler, the DHW component provides domestic hot water to a bar sink, powder room and a full bath. My lead tech, Brian Golden,
HYDRONICS
Foley Mechanical lead tech Brian Golden performing a startup of the Alta. Photo: Lisa Helfert Photography Lead tech Brian Golden checking the gas pressure on the Alta. Photo: Lisa Helfert Photography
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