Burnham Water boiler, ALP080, ALP105, ALP150, ALP210 Installation, Operating And Service Instructions

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As an ENERGY STAR

ENERGY STAR

WaRning: Improper installation, adjustment, alteration, service or maintenance can cause property damage,

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

Partner, Burnham by U.S. Boiler Company has determined that the Alpine™ Series meets the

guidelines for energy efciency established by the United States Environmental Protection Agency (EPA).

101602-01R9-9/10

Price - $5.00

IMPORTANT INFORMATION - READ CAREFULLY

NOTE: The equipment shall be installed in accordance with those installation regulations enforced in the area where the

installation is to be made. These regulations shall be carefully followed in all cases. Authorities having jurisdiction shall be consulted before installations are made.

All wiring on boilers installed in the USA shall be made in accordance with the National Electrical Code and/or local regulations. All wiring on boilers installed in Canada shall be made in accordance with the Canadian Electrical Code and/or local regulations.

The City of New York requires a Licensed Master Plumber supervise the installation of this product. The Massachusetts Board of Plumbers and Gas Fitters has approved the Alpine™ Series boiler. See the Massachusetts Board of

Plumbers and Gas Fitters website, http://license.reg.state.ma.us/pubLic/pl_products/pb_pre_form.asp for the latest Approval Code or ask your local Sales Representative.

The Commonwealth of Massachusetts requires 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 important information concerning product life.

DangER

indicates an imminently hazardous situation which, if not avoided, will result in death, serious injury or substantial property damage.

WaRning

indicates a potentially hazardous situation which, if not avoided, could result in death, serious injury or substantial property damage.

indicates a potentially hazardous situation which, if not avoided, may result in moderate or minor injury or property damage.

indicates special instructions on installation, operation, or maintenance which are important but not related to personal injury hazards.

CaUTiOn

nOTiCE

DangER

DO NOT store or use gasoline or other ammable vapors or liquids in the vicinity of this or any other

appliance. if you smell gas vapors, nO nOT try to operate any appliance - DO nOT touch any electrical switch or use

any phone in the building. immediately, call the gas supplier from a remotely located phone. Follow the gas

supplier’s instructions or if the supplier is unavailable, contact the re department.

Special Installation Requirements for Massachusetts

A. For all sidewall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or

in part for residential purposes and where the sidewall exhaust vent termination is less than seven (7) feet above grade, the

following requirements shall be satised:

1. If there is no carbon monoxide detector with an alarm already installed in compliance with the most current edition of NFPA 720, NFPA 70 and the Massachusetts State Building Code in the residential unit served by the sidewall horizontally vented gas fueled equipment, a battery operated carbon monoxide detector with an alarm shall be installed in compliance with the most current edition of NFPA 720, NFPA 70 and the Massachusetts State Building Code.

In addition to the above requirements, if there is not one already present, a carbon monoxide detector with an alarm

and a battery back-up shall be installed and located in accordance with the installation requirements supplied with the

detector on the oor level where the gas equipment is installed. The carbon monoxide detector with an alarm shall

comply with 527 CMR, ANSI/UL 2034 Standards or CSA 6.19 and the most current edition of NFPA 720. In the event that the requirements of this subdivision can not be met at the time of the completion of the installation of the equipment, the installer shall have a period of thirty (30) days to comply with this requirement; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed in compliance with the most current edition of NFPA 720, NFPA 70 and the Massachusetts State Building Code. In the event that the sidewall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the carbon monoxide detector

may be installed on the next adjacent habitable oor level. Such detector may be a battery operated carbon monoxide

detector with an alarm and shall be installed in compliance with the most current edition of NFPA 720, NFPA 70 and the Massachusetts State Building Code.

3. A metal or plastic identication plate shall be permanently mounted to the exterior of the building at a minimum height

of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, “GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.

4. A nal inspection by the state or local gas inspector of the sidewall horizontally vented equipment shall not be performed

until proof is provided that the state or local electrical inspector having jurisdiction has granted a permit for installation of carbon monoxide detectors and alarms as required above.

B. EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a) 1 through 4:

1. The equipment listed in Chapter 10 entitled “Equipment Not Required To Be Vented” in the most current edition of NFPA 54 as adopted by the Board; and

2. Product Approved sidewall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes.

When the manufacturer of Product Approved sidewall horizontally vented gas equipment provides a venting system design

or venting system components with the equipment, the instructions for installation of the equipment and the venting system shall include:

A complete parts list for the venting system design or venting system; and

2. Detailed instructions for the installation of the venting system design or the venting system components.

D. When the manufacturer of a Product Approved sidewall horizontally vented gas fueled equipment does not provide the parts

for venting ue gases, but identies “special venting systems”, the following shall be satised:

1. The referenced “special venting system” instructions shall be included with the appliance or equipment installation instructions; and

2. The “special venting systems” shall be Product Approved by the Board, and the instructions for that system shall include a parts list and detailed installation instructions.

E. A copy of all installation instructions for all Product Approved sidewall horizontally vented gas fueled equipment, all venting

instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation.

WaRning

This boiler requires regular maintenance and service to operate safely. Follow the instructions contained

in this manual. improper installation, adjustment, alteration, service or maintenance can cause property damage, personal

injury or loss of life. Read and understand the entire manual before attempting installation, start-up operation, knowledgeable installer or service agency

This boiler must be properly vented.

This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate

combustion and ventilation air. The interior of the venting system must be inspected and cleaned before the start of the heating season

and

should be inspected periodically throughout the heating season for any obstructions. a clean and

unobstructed venting system is necessary to allow noxious fumes that could cause injury or loss of life

to vent safely and will contribute toward maintaining the boiler’s efciency.

installation is not complete unless a pressure relief valve is installed into the tapping located on left side of appliance. - See the Water Piping and Trim Section of this manual for details.

This boiler is supplied with safety devices which may cause the boiler to shut down and not re-start without unattended in cold weather; or appropriate safeguards and alarms should be installed on the heating system to prevent damage if the boiler is inoperative.

or service. installation and service must be performed only by an experienced, skilled, and

service. if damage due to frozen pipes is a possibility, the heating system should not be left

This boiler contains very hot water under high pressure. Do not unscrew any pipe ttings nor attempt

to disconnect any components of this boiler without positively assuring the water is cool and has no

pressure. Always wear protective clothing and equipment when installing, starting up or servicing this

boiler to prevent scald injuries. Do not rely on the pressure and temperature gauges to determine the temperature and pressure of the boiler. This boiler contains components which become very hot when the boiler is operating. Do not touch any components unless they are cool.

Boiler materials of construction, products of combustion and the fuel contain alumina, silica, heavy metals, carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or harmful substances which can cause death or serious injury and which are known to the state of California to cause cancer, birth defects and

other reproductive harm. Always use proper safety clothing, respirators and equipment when servicing

or working nearby the appliance. Failure to follow all instructions in the proper order can cause personal injury or death. Read all instruc-

tions, including all those contained in component manufacturers manuals which are provided with the boiler before installing, starting up, operating, maintaining or servicing.

ll cover plates, enclosures and guards must be in place at all times.

nOTiCE

This boiler has a limited warranty, a copy of which is printed on the back of this manual. it is the responsibility of the installing contractor to see that all controls are correctly installed and are operating properly when the installation is complete.

TABLE OF CONTENTS

I. Product Description, Specications and Dimensional Data...................... 6

II. Pre-Installation & Boiler Mounting ............................................................ 13

III. Unpacking Boiler........................................................................................ 17

IV. Venting...................................................................................................... 18

General Guidelines............................................................................... 18

CPVC/PVC Venting.............................................................................. 21

Stainless Steel Venting........................................................................ 29

Concentric Polypropylene.................................................................... 31

Removing the Existing Boiler............................................................... 38

V. Condensate Disposal................................................................................. 39

VI. Water Piping and Trim............................................................................... 41

VII. Gas Piping ................................................................................................ 50

VIII. Electrical ................................................................................................... 54

IX. Boiler Stacking ......................................................................................... 61

X. Modular Installation................................................................................... 63

General Guidelines.............................................................................. 63

Venting................................................................................................ 63

Water Piping and Trim......................................................................... 66

D. Gas Piping........................................................................................... 66

Electrical.............................................................................................. 76

. External Modular Boiler Controls......................................................... 76

Modular Boiler Operating Information.................................................. 77

Major Features............................................................................... 77

Operating Modes........................................................................... 79

Required Equipment and Setup..................................................... 81

Adjusting Parameters.................................................................... 83

XI. System Start-up ...................................................................................... 86

XII. Operation ................................................................................................. 92

Major Features..................................................................................... 92

Operating Mode................................................................................... 96

1. Home Screen................................................................................ 96

Boiler Status Screen...................................................................... 97

Controls Start-up Checklist.................................................................. 98

User Interface...................................................................................... 99

Using The Display.......................................................................... 99

Selecting View Mode Options........................................................ 99

Help Screens................................................................................. 100

Entering Adjust Mode.................................................................... 101

Adjusting Parameters........................................................................... 102

XIII. Service and Maintenance ......................................................................... 110

XIV. Troubleshooting........................................................................................ 114

XV. Repair Parts ............................................................................................. 117

Appendix B - Figures................................................................................ 126

Appendix C - Tables.................................................................................. 129

Warranty...........................................................................................Back Page

I. Product Description, Specications and Dimensional Data

Alpine™ Series boilers are condensing high efciency

gas-red direct vent hot water boilers designed for use

in forced hot water space or space heating with indirect domestic hot water heating systems, where supply water temperature does not exceed 210°F. These boilers have special coil type stainless steel heat exchangers, constructed, tested and stamped per Section IV ‘Heating Boilers’ of

Table 1: Dimensional Data (See Figures 1a, 1B, 1C & 1D)

Dimension

A - Inch

(mm)

B - Inch

(mm)

C - Inch

(mm)

D - Inch

(mm)

E - Inch

(mm)

Gas Inlet F

(FPT)

Return G

(FPT)

Supply H

(FPT)

Condensate Drain J *

Boiler Two-Pipe

CPVC/PVC Vent Connector

(Figs. 1A, 1C, 1D) - Inch

Boiler

CPVC Vent Connector/Pipe

(Fig. 1B) - Inch

Boiler Inlet Air Connector

(Fig. 1B) - Inch

Approx. Shipping Weight

(LBS)

ALP080

12-9/16

(1)

ALP105

(320)

5-5/8

(142)

9-5/16

(237)

* Factory Provided Socket End Compression Pipe Joining Clamp

3 x 3 3 x 4 4 x 4

3” 3” 4” 4” N/A N/A N/A

137 155 182 206 256 304 350

(1)

ALP150

(356)

10-3/4

(273)

19-11/16

(500)

5-13/16

(147)

7-5/16

(186)

16-7/16

(417)

5-15/16

(151)

1/2” 3/4” 3/4” 3/4”

1” 1-1/4” 1-1/2”

for 3/4” Schedule 40 PVC Pipe

3” N/A N/A N/A

ASME Boiler and Pressure Vessel Code, which provide a maximum heat transfer and simultaneous protection against

ue gas product corrosion. These boilers are not designed

for use in gravity hot water space heating systems or

systems containing signicant amount of dissolved oxygen

(swimming pool water heating, direct domestic hot water heating, etc.).

Boiler Model

(1)

ALP210

23-15/16

(608)

17-1/8

(435)

(1)

ALP285

21-13/16

(554)

7-5/16

(185)

14-1/8

(358)

(456)

12-1/4

(312)

(2)

ALP399

28-7/8

(734)

6-3/16

(157)

13-1/16

(332)

23-3/4

(602)

15-13/16

(402)

(2)

ALP500

44-7/8

(1140)

22-1/8

(562)

(737)

39-11/16

(1008)

29-3/8

(752)

(2)

nOTES:

(1)

- These boiler models available as either Floor mounted (sufx F) or, Wall mounted (sufx W).

(2)

- These boiler models available as Floor mounted (sufx F) only.

I. Product Description, Specications and Dimensional Data (continued)

Figure 1a: alpine™ - Models aLP080 thru aLP210 (Floor Mounted)

I. Product Description, Specications and Dimensional Data (continued)

Figure 1B: alpine™ - Models aLP080 thru aLP210 (Wall Mounted)

I. Product Description, Specications and Dimensional Data (continued)

Figure 1C: alpine™ - Models aLP285 thru aLP399 (Floor Mounted Only)

I. Product Description, Specications and Dimensional Data (continued)

Figure 1D: alpine™ - Model aLP500 (Floor Mounted Only)

I. Product Description, Specications and Dimensional Data (continued)

Table 2a: Rating Data - Models aLP080 thru aLP500 (0 to 2000 Feet Elevation above Sea Level)

alpine Series gas-Fired Boilers

* Model

Number

ALP080 16 80 73 63 95 0.6 7.3 ALP105 21 105 96 83 95 0.7 9.1 ALP150 30 150 138 120 95 1.3 16.4 ALP210 42 210 194 169 95 1.7 21.8 ALP285 57 285 265 230 95 2.4 29.1 ALP399 80 399 377 328 94 95 3.4 41.8 ALP500 100 500 475 413 95 95 4.2 50.8

(MBH)

Min. Max.

** Output

(MBH)

Input

Net I=B=R

Ratings

Water (MBH)

AFUE

Thermal

Efciency

(%)

Combustion

Efciency (%)

Boiler Water

Volume

(Gal.)

Heat Transfer

Area

(Sq. Ft.)

* Add Sufx “F” for Floor mounted Models or Sufx “W” for Wall mounted Models. notes: ** DOE Heating Capacity (ALP080 thru ALP285); Gross Output (ALP399 thru ALP500)

Maximum Working Pressure, Water - 30 PSI Shipped from Factory (std.); 50 PSI, 80 PSI and 100 PSI - Optional (ALP080 thru ALP285) Maximum Working Pressure, Water - 50 PSI Shipped from Factory (std.); 80 PSI and 100 PSI - Optional (ALP399 thru ALP500) Maximum Allowable Temperature, Water - 210°F, Maximum Firing Rate Target Setpoint is 190°F, Automatic Reset High Limit Setpoint is 200°F and Manual Reset High Limit Setpoint is 210°F. Boilers are factory shipped as Natural Gas builds and have to be eld adjusted for LP gas application. Refer to ‘System Start- Up Section of this manual for detailed procedure.

Ratings shown are for installations at sea level and elevations up to 2000 Feet. For elevations above 2000 Feet, ratings should be reduced at the rate of four percent (4%) for each 1000 Feet above sea level.

Table 2B: Rating Data - Models aLP080 thru aLP500 (2001 to 7000 Feet Elevation above Sea Level)

alpine Series gas-Fired Boilers

Model

Number *

ALP080 27 80 73 63 95 0.6 7.3 ALP105 35 105 96 83 95 0.7 9.1 ALP150 50 150 138 120 95 1.3 16.4 ALP210 70 210 194 169 95 1.7 21.8 ALP285 57 285 265 230 95 2.4 29.1 ALP399 80 399 377 328 94 95 3.4 41.8 ALP500 100 500 475 413 95 95 4.2 50.8

(MBH)

Min. Max.

** Output

(MBH)

* Add Sufx “F” for Floor mounted Models or Sufx “W” for Wall mounted Models. notes: ** DOE Heating Capacity (ALP080 thru ALP285); Gross Output (ALP399 thru ALP500)

Maximum Working Pressure, Water - 30 PSI Shipped from Factory (std.); 50 PSI, 80 PSI and 100 PSI - Optional

Maximum Working Pressure, Water - 50 PSI Shipped from Factory (std.); 80 PSI and 100 PSI - Optional (ALP399 thru ALP500) Maximum Allowable Temperature, Water - 210°F, Maximum Firing Rate Target Setpoint is 190°F, Automatic Reset High Limit Setpoint is 200°F and Manual Reset High Limit Setpoint is 210°F. Boilers are factory shipped as Natural Gas builds and have to be eld adjusted for LP gas application. Refer to ‘System Start- Up” Section of this manual for detailed procedure.

For elevations above 2000 Feet, ratings should be reduced at the rate of four percent (4%) for each 1000 Feet above sea level.

Input

Net I=B=R

Ratings

Water (MBH)

AFUE

Thermal

Efciency

(%)

Combustion

Efciency (%)

Boiler Water

Volume

(Gal.)

Heat Transfer

Area (Sq. Ft.)

I. Product Description, Specications and Dimensional Data (continued)

Table 2C: Rating Data - Models aLP150 thru aLP285 (7001 to 10,000 Feet Elevation above Sea Level)

alpine Series gas-Fired Boilers

Model

Number *

ALP150 38 113 104 90 95 1.3 16.4 ALP210 53 158 145 126 95 1.7 21.8 ALP285 68 204 188 163 95 2.4 29.1

(MBH)

Min. Max.

** Output

(MBH)

Input

Net I=B=R

Ratings

Water (MBH)

AFUE

Thermal

Efciency

(%)

Combustion

Efciency (%)

Boiler Water

Volume

(Gal.)

Heat Transfer

Area (Sq. Ft.)

* Add Sufx “F” for Floor mounted Models or Sufx “W” for Wall mounted Models. notes: ** DOE Heating Capacity (ALP150 thru ALP285)

Maximum Working Pressure, Water - 30 PSI Shipped from Factory (std.); 50 PSI - Optional

Maximum Allowable Temperature, Water - 210°F

Boilers are factory shipped as Natural Gas builds only.

Input has been de rated for noted elevation above sea level.

ii. Pre-installation & Boiler Mounting

WaRning

if you do not follow these instructions exactly,

a re or explosion may result causing property

damage or personal injury.

nOTiCE

Due to the low water content of the boiler, missizing of the boiler with regard to the heating system load will result in excessive boiler cycling and accelerated component failure. U.S. Boiler DOES nOT warrant failures caused by mis-sized boiler applications. DO nOT oversize the boiler to the system. Modular boiler installations greatly reduce the likelihood of boiler oversizing.

A. Installation must conform to the requirements of the

authority having jurisdiction. In the absence of such requirements, installation must conform to the National Fuel Gas Code, NFPA 54/ANSI Z223.1, and/or CAN/ CSA B149.1 Installation Codes.

B. Appliance is design certied for installation on

combustible ooring. Do not install boiler on

carpeting.

C. Provide clearance between boiler jacket and

combustible material in accordance with local re

ordinance. Refer to Figures 2A and 2B for minimum listed clearances from combustible material. Recommended service clearance is 24 inches from left side, front, top and rear of the boiler. Recommended front clearance may be reduced to the combustible material clearance providing:

1. Access to boiler front is provided through a door or removable front access panel.

2. Access is provided to the condensate trap located underneath the heat exchanger.

D. Protect gas ignition system components from water

(dripping, spraying, rain, etc.) during boiler operation and service (circulator replacement, condensate trap, control replacement, etc.).

E. Provide combustion and ventilation air in accordance

with applicable provisions of local building codes, or: USA - National Fuel Gas Code, NFPA 54/ANSI Z223.1, Air for Combustion and Ventilation;

Canada - Natural Gas and Propane Installation Code,

CAN/CSA-B149.1, Venting Systems and Air Supply for Appliances.

WaRning

F. The boiler should be located so as to minimize the

length of the vent system. The PVC combustion air piping, or the optional concentric vent piping, containing integral combustion air inlet piping, must terminate where outdoor air is available for combustion and away from areas that may contaminate combustion air. In particular, avoid areas near chemical products

containing chlorines, chlorouorocarbons , paint

removers, cleaning solvents and detergents. Avoid

areas containing saw dust, loose insulation bers, dry

wall dust etc.

CaUTiOn

avoid operating this boiler in an environment

where saw dust, loose insulation bers, dry wall

dust, etc. are present. if boiler is operated under these conditions, the burner interior and ports must be cleaned and inspected daily to insure proper operation.

G. General.

1. Alpine boilers are intended for installations in an

area with a oor drain, or, in a suitable drain pan to

prevent any leaks or relief valve discharge to cause property damage

2. Alpine boilers are not intended to support external piping and venting. All external piping and venting must be supported independently of the boiler.

3. Alpine boilers must be installed level to prevent condensate from backing up inside the boiler.

4. Alpine boilers can be installed either as oor

standing (ALP080 thru ALP500), or, as wall hung

(ALP080 thru ALP210). Factory assembled oor standing models are identied with sufx F in a

boiler model code (example – ALP210F-1L02).

Factory assembled wall hung models are identied with sufx W in a boiler model code (example

– ALP210W-1L02).

5. Boiler Floor Standing Installation: a. For basement installation provide a solid base

such as concrete, where oor is not level, or, water may be encountered on the oor around

boiler. Floor must be able to support weight of boiler, water and all additional system components.

b. Boiler must be level to prevent condensate from

backing up inside the boiler.

c. Insure there is adequate space for condensate

piping or a condensate pump if required.

Adequate combustion and ventilation air must

be provided to assure proper combustion.

ii. Pre-installation & Boiler Mounting (continued)

6. Boiler Wall Hung Installation: a. If the boiler is installed on a framed wall,

minimum acceptable framing is 2 x 4 studs on 16” centers. The boiler mounting holes are on 16” centers for installation between two studs at the standard spacing. In cases where the boiler cannot be centered between the studs, or where the studs are spaced closer than 16” apart, the boiler may be anchored to ¾” plywood or horizontal 2 x 4’s anchored to the studs.

CaUTiOn

alpine boiler approximate dry weights: aLP080W – 98 lbs; aLP105W – 112 lbs;

aLP150W – 136 lbs: aLP210W – 150 lbs

Two people are required to safely lift these

boilers onto the installed wall mounting bracket.

Make sure that wall mounting bracket is anchored to a structure capable of supporting the weight of the boiler and attached piping

when lled with water. Jurisdictions in areas

subject to earthquakes may have special re-

quirements for supporting these boilers. Such local requirements take precedence over the requirements shown below.

Locate Wall Mounting Bracket Kit carton (p/n

102988-01) enclosed inside boiler carton. The kit contains Wall Mounting Bracket, Bottom Securing Bracket, (4) 5/16” x 2” long hex head

lag screws, (4) 5/16” at plated washers and (2)

#8 x ½” Phillips round head sheet metal screws.

5/16” x 2” lag screws and 5/16” plated washers

are intended for mounting the boiler directly onto studs covered with ½” sheet rock. When the boiler is attached to other types of construction, such as masonry, use fasteners capable of supporting the weight of the boiler and attached piping in accordance with good construction practice and applicable local codes.

d. Make sure that the surface to which the boiler is

mounted is plumb.

e. Before mounting the boiler, make sure that wall

selected does not have any framing or other construction that will interfere with the vent pipe penetration.

f. Once a suitable location has been selected for the

boiler, and any needed modications have been

made to the wall, use Figure 2C to locate and layout holes “A” and “B”. These holes must be positioned on mounting stud centers, if the boiler is installed on a framed wall. Make sure that

the horizontal centerline of these holes is level. Holes “C” and “D” may also be drilled at this time, or after the boiler is hung on the wall. If the 5/16 x 2” lag screws are used, drill 3/16” pilot holes.

g. An alternate way to locate/mark holes “A”

and “B” is to use template P/N 102986-01 enclosed into Vent Part Carton [P/N 10298101 (ALP080W/105W) or, P/N 102981-02 (ALP150W/210W)], which can be found inside boiler carton.

CaUTiOn

The outer edges of the template represent minimum side, top and bottom clearances to combustible material. if the template needs to be

cut to t into a selected location, it would indicate

the minimum clearances to combustible material are not met.

h. Attach the wall hanging bracket using the 5/16”

x 2” lag screws and 5/16” plated washers, or other suitable anchors as appropriate (Figure 2D). Make sure the bracket is level.

Attach Bottom Securing Bracket to boiler air box

with two #8 x ½” Phillips round head sheet metal screws. Refer to Figure 2D for details.

j. Hang the boiler on the installed wall bracket as

shown in Figure 2D.

k. If not already done in Step (4) locate and drill

holes “C” and “D” using the ob-round slots in the Bottom Securing Bracket. Secure the Bracket to the wall using the 5/16” x 2” lag screws and 5/16” plated washers, or other fasteners as appropriate (Figure 2D).

l. Verify that the front of the boiler is plumb. If it

is not, install shims (installer provided) at holes “C” and “D” between the Bottom Securing Bracket and the wall to adjust.

CaUTiOn

When positioning the template in the desired location on the wall insure that the minimum clearances to combustible material at adjacent walls and ceiling are maintained. Consult Figures 2a thru 2C in this manual. Be sure to allow space at the boiler left side for gas and water connections, as well as for access to the condensate trap and boiler controls for servicing.

m. Remove Access Panel and Access Panel Gasket

from zip lock plastic bag (placed inside 10298101 or 102981-02 Vent Kit carton).

ii. Pre-installation & Boiler Mounting (continued)

Figure 2a: Clearances To Combustible and non-combustible Material, Floor Standing

Figure 2B: Clearances To Combustible and non-combustible Material, Wall Mounted

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

3 4

WALL MOUNTING BRACKET

CENTER LINE

BOTTOM SECURING

BRACKET CENTER LINE

2.0" MIN. CLEARANCE TO COMBUSTIBLE

'HOLE B'

" DIA. PILOT HOLES

FOR

" LAG SCREWS

(4 PLACES)

ii. Pre-installation & Boiler Mounting (continued)

n. Place Access Panel Gasket adhesive side

(protective paper) down onto Access Panel

underside and align gasket edges ush with panel

edges. Peel off protective paper from one end of the gasket to expose adhesive, then place the gasket onto the panel aligning gasket and panel side, top and bottom edges, and press the gasket lightly down. Continue peeling of protective paper and positioning the gasket in place while insuring edge alignment. Once the gasket is fully in place and edges are aligned, press the

gasket rmly in position.

o. Set the panel with gasket aside.

p. See Section IV Venting; paragraph “Field

Installation of CPVC Vent Pipe - Wall Mounted Boiler Builds” for instructions on attaching the vent system to the boiler.

q. After the boiler has been piped, wired, connected

to vent and combustion air system piping and combustion performance testing completed per Section XI “System Start-up”, install Access Panel/Gasket assembly and secure with provided four #8 x ½” black oxide Phillips head sheet metal screws (located in coin envelope inside zip lock plastic bag). See Figure 2E “access Panel and Gasket Installation”.

Figure 2C: Wall Mounting Hole Location / Layout

ii. Pre-installation & Boiler Mounting (continued)

iii. Unpacking Boiler

CaUTiOn

Figure 2D: Bottom Mounting Bracket installation / Boiler Wall Mounting

Figure 2E: access Panel and gasket installation

D. Remove boiler from cardboard positioning sleeve on

shipping skid.

Do not drop boiler.

A. Move boiler to approximate installed position. B. Remove all crate fasteners. C. Lift and remove outside container.

WaRning

installation of this boiler should be undertaken only by trained and skilled personnel from a

qualied service agency.

E. Move boiler to its permanent location.

iV. Venting

WaRning

Failure to vent this boiler in accordance with these instructions could cause products of combustion to enter the building resulting in severe property damage, personal injury or death.

Do not interchange vent systems or materials unless otherwise specied.

The use of thermal insulation covering pipe and ttings is prohibited.

Do not use a barometric damper, draft hood or vent damper with this boiler.

When using the CPVC/PVC vent option, the use of CPVC is required when venting in vertical or horizontal

chase ways. The CPVC vent materials supplied with this boiler do not comply with B1

proved for use in Canadian jurisdictions that require vent systems be listed to ULC S636-2008. In

these jurisdictions, vent this boiler using either stainless steel Special Class iiB venting system.

Do not locate vent termination where exposed to prevailing winds. Moisture and ice may form on surface around vent termination. To prevent deterioration, surface must be in good repair (sealed, painted, etc.).

Do not locate air intake vent termination where chlorines, chlorouorocarbons (CFC’s), petroleum

distillates, detergents, volatile vapors or other chemicals are present. Severe boiler corrosion and failure will result.

The use of cellular core PVC (

aSTM F891) is prohibited.

49.1.S1-07 and are not ap-

gas vent or a listed ULC S636

Do not locate vent termination under a deck.

Do not reduce specied diameters of vent and combustion air piping.

When installing vent pipe through chimney, as a chase, no other appliance can be vented into the chimney.

Do not allow low spots in the vent where condensate may pool.

A. General Guidelines

1. Vent system installation must be in accordance with National Fuel Gas Code, NFPA 54/ANSI Z221.3 or applicable provisions of local building

codes. Contact local building or re ofcials about

restrictions and installation inspection in your area.

2. The Alpine™ is designed to be installed as a Direct Vent (sealed combustion) boiler. The air for combustion is supplied directly to the burner

enclosure from outdoors and ue gases are vented

directly outdoors (through wall or roof).

3. The following combustion air/vent system options are approved for use with the Alpine™ boilers (refer to Table 3):

• Two-Pipe CPVC/PVC Vent/Combustion Air

System - separate CPVC/PVC pipe serves to expel products of combustion and separate PVC pipe delivers fresh outdoor combustion air.

Refer to Part B for specic details.

• Two-Pipe Stainless Steel Vent/Combustion Air

System - separate stainless steel pipe serves to expel products of combustion. Separate PVC or galvanized pipe delivers fresh outdoor air. Refer

to Part C for specic details.

• Concentric Inner Polypropylene Vent and Outer Steel Combustion Air System

- the assembly consists of inner re resistant

polypropylene vent pipe and outer steel pipe casing. The inner pipe serves as conduit to expel products of combustion, while outdoor fresh combustion air is drawn through the space between the inner and outer pipes. Refer to Part

D for specic details.

Horizontal vent pipe must maintain a 1/4" per foot

4. slope down towards the boiler.

5. Horizontal combustion air pipe must maintain a minimum ¼" per foot slope down towards terminal, when possible. If not, slope toward boiler.

6. Do not install venting system components on

the exterior of the building except as specically

required by these instructions (refer to Figure 3):

• Vent terminals must be at least 1 foot from any

door, window, or gravity inlet into the building.

• Maintain the correct clearance and orientation

between the vent and air intake terminals. The vent and air intake terminals must be at the same height and their center lines must be spaced apart 12” minimum. Locate air intake termination on the same wall as the vent termination if possible,

iV. Venting (continued)

Table 3: Vent/Combustion air System Options

Boiler Build

Floor Standing

or Wall Hung

Floor Standing

Only

Floor Standing

Only

Approved Direct

Vent System

Two-Pipe,

CPVC/PVC

Vent and PVC

air intake

(Factory Standard)

Two-Pipe,

Stainless Steel Vent

and PVC/galvanized

steel air intake

(Available Optional)

Concentric, Inner

Polypropylene Vent and Outer Steel Air

intake (Available

Optional)

Vent

Material

CPVC/PVC

Stainless Steel

Polypropylene

Orientation Termination Description Figures

The system includes separate CPVC vent pipe and PVC air intake pipe terminating thru sidewall with individual penetrations for the vent and air intake piping and separate terminals (tees).

Same as above but separate snorkel

type terminals.

The system includes separate CPVC vent pipe and PVC air intake pipe terminating thru roof with individual penetrations for the vent and air intake piping and separate vertical

terminals.

The system includes separate stainless steel vent pipe and PVC/galvanized steel air intake pipe terminating thru sidewall with individual penetrations for the vent and air intake piping and separate

terminals

Same as above but separate snorkel

type terminals.

The system includes separate stainless steel vent pipe and PVC/galvanized steel air intake pipe terminating thru roof with individual penetrations for the vent and air intake piping and separate terminals.

Concentric vent/air pipe terminates thru sidewall.

Concentric vent/air pipe terminates

thru roof.

4 thru 9 4A

4, 5A, 5B, 6, 7, 9, 10

4, 5A, 5B,

6, 9, 11

8, 13

10, 13

11, 12, 13

14 thru 21

14, 15, 16, 17,

22 thru 26

Horizontal

Optional Vertical

Horizontal

Vertical

Horizontal

Vertical

Standard

(thru sidewall)

Optional

Snorkel

(thru sidewall)

Vertical

(thru roof)

Standard

(thru sidewall)

Optional

Snorkel

(thru sidewall)

Vertical

(thru roof)

Horizontal

(Wall) Terminal

Vertical (Roof)

Terminal

Component

Table

8A & 8B C.

10 D.

Part

Figure 3: Location of Vent Terminal Relative to Windows, Doors, grades, Overhangs, Meters and Forced air inlets (Concentric Terminal Shown - Two-Pipe System Vent Terminal to be installed in same location Two-Pipe System air intake Terminal not Shown)

iV. Venting (continued)

to prevent nuisance boiler shutdowns. However, boiler may be installed with vertical venting and sidewall combustion air inlet or visa versa, if installation conditions do not allow alternate arrangement.

• The bottom of the vent and air intake terminal must be at least 12" (18" in Canada) above the normal snow line. In no case should they be less than 12" above grade level.

• The bottom of the vent terminal must be at least 7 feet above a public walkway.

• Do not install the vent terminal directly over windows or doors.

• The bottom of the vent terminal must be at least 3 feet above any forced air inlet located within 10 feet.

• A clearance of at least 4 feet horizontally must be maintained between the vent terminal and gas meters, electric meters, regulators, and relief equipment. Do not install vent terminal over this equipment.

• Do not locate the vent terminal under decks or similar structures.

• Minimum twelve (12) inches vertically from any roof overhang twelve (12) inches or less wide.

If a roof overhang width exceeds twelve (12)

inches the terminal vertical clearance must be

increased to avoid ue vapor condensation.

• Top of vent terminal must be at least 5 feet below

eaves, softs, or overhangs. Maximum depth of

overhang is 3 ft.

• If window and/or air inlet is within four (4) feet of an inside corner, then terminal must be at least six (6) feet from adjoining wall of inside corner.

• Concentric - Minimum twelve (12) inches horizontally from a building corner.

• Under certain conditions, water in the ue gas

may condense, and possibly freeze, on objects around the terminal including on the structure itself. If these objects are subject to damage by

ue gas condensate, they should be moved or

protected.

• If possible, install the vent and air intake terminals on a wall away from the prevailing wind. Reliable operation of this boiler cannot be guaranteed if the terminal is subjected to winds in excess of 40 mph.

• Air intake terminal must not terminate in areas that might contain combustion air contaminates, such as near swimming pools.

• For sidewall venting the minimum horizontal distance between any adjacent individual module (boiler) vent terminations is twelve (12) inches.

Increasing this distance is recommended to avoid

frost damage to building surfaces where vent terminations are placed.

CaUTiOn

installing multiple individual module (boiler) vent terminations too close together may result in cross contamination and combustion product water vapor condensation on building surfaces, where

vent termination are placed, and subsequent

frost damage. To avoid/minimize frost damage, extend the distance from building surfaces to vent termination end and increase the horizontal distance between adjacent vent terminations.

• The minimum horizontal distance between any adjacent individual module (boiler) roof vent terminations is one (1) foot.

Use noncombustible ¾" pipe strap to support

7. horizontal runs and maintain vent location and slope while preventing sags in pipe. Do not restrict thermal expansion or movement of vent system. Maximum support spacing four (4) feet. Avoid low spots where condensate may pool. Do not penetrate any part of the vent system with fasteners.

8. Maintain minimum clearance to combustible materials. See Figures 2A and 2B for details.

9. Enclose vent passing through occupied or unoccupied spaces above boiler with the material

having a re resistance rating of at least equal to the rating of adjoining oor or ceiling.

Note: For one or two family dwellings, re

resistance rating requirement may not need to be met, but is recommended.

10. Multiple individual module vertical vent pipes may be piped through a common conduit or chase so that one roof penetration may be made.

iV. Venting (continued)

B. CPVC/PVC Venting

WaRning

all CPVC vent components (supplied with boiler) must be used for near-boiler vent piping before transitioning to Schedule 40 PVC pipe (aSTM

2665) components for remainder of vent system.

WaRning

CPVC vent components must be used within any interior space where air cannot circulate freely, such as air inside a stud wall, and in any boiler closet.

Table 4a: CPVC/PVC Vent & air intake Components included With Boiler

LP080 & aLP105

Vent & air intake Components

3” Schedule 40 PVC Tee (Vent & Air Intake Terminals) 4” Schedule 40 PVC Tee (Vent & Air Intake Terminals)

3” Stainless Steel Rodent Screen 102191-01 2 1 N/A 4” Stainless Steel Rodent Screen 102191-02 N/A 1 2 3” x 30” Schedule 40 CPVC Pipe 102193-01 1 1 N/A 4” x 30” Schedule 40 CPVC Pipe 102193-02 N/A N/A 1 3” Schedule 80 CPVC 90° Elbow 102192-01 1 1 1 4” Schedule 80 CPVC 90° Elbow 102192-02 N/A N/A 1

4 oz. Bottle of Transition Cement 102195-01 1 1 1 4 oz. Bottle of Primer 102194-01 1 1 1

3" Vent/3" Combustion Air CPVC/PVC

Connector

3" Vent/4" Combustion Air CPVC/PVC

Connector

4" Vent/4" Combustion Air CPVC/PVC

Connector

3" Vent/3" Combustion Air CPVC/PVC

Connector Gasket

4" Vent/4" Combustion Air CPVC/PVC

Connector Gasket

Part

umber

102190-01 2 1 N/A

102190-02 N/A 1 2

102183-01 1 N/A N/A

102183-02 N/A 1 N/A

102183-03 N/A N/A 1

102185-01 1 N/A N/A

102185-02 N/A 1 1

Table 4B: CPVC/PVC Vent & Air Intake Components (Installer Provided) required for Optional Vertical

(Roof) Termination

Vent Components

3" Schedule 40 PVC Coupler

4" Schedule 40 PVC Coupler N/A 1 1

3" Schedule 40 PVC 90° Elbow

4" Schedule 40 PVC 90° Elbow

3" Schedule 40 CPVC Pipe x ½ ft. min. horizontal run

4" Schedule 40 CPVC Pipe x ½ ft. min. horizontal run

Standard Termination

(P/

Part

number

N/A

Supplied by

Others

When using the CPVC/PVC vent options, the use

of CPVC is required when venting in vertical or

horizontal chase ways.

Components and Length Restrictions

1. a. See Table 4A for CPVC/PVC Vent & Air Intake

Components included with boiler, Table 4B for CPVC/PVC Vent and Air Intake Components (Installer Provided) required for Optional Vertical (Roof) Termination and Table 4C for CPVC/PVC Vent and Air Intake Components (Installer Provided) required for Optional Horizontal (Snorkel) Termination.

Quantity

Vent Kit

n 102189-01)

includes

LP080 & aLP105

Vertical (Roof)

Termination

1 N/A N/A

2 N/A N/A

N/A 2 2

N/A 1 1

aLP150 & aLP210

Standard Termination

Vent Kit

(P/n 102189-02)

includes

Quantity

LP150 & aLP210

Vertical (Roof)

Termination

N/A

aLP285 thru aLP500

Standard Termination

(P/n 102189-03)

aLP285 thru aLP500

Vertical (Roof)

Termination

Vent Kit

includes

N/A

iV. Venting (continued)

Table 4C: CPVC/PVC Vent & Air Intake Components (Installer Provided) required for Optional Horizontal

(Snorkel) Termination

Quantity

Vent Components

3" Schedule 40 PVC Pipe x up to 7 ft. max. vertical run

4" Schedule 40 PVC Pipe x up to 7 ft. max. vertical run N/A 1 2

3" Schedule 40 PVC 90° Elbow

4" Schedule 40 PVC 90° Elbow

3" Schedule 40 PVC Pipe x ½ ft. min. horizontal run

4" Schedule 40 PVC Pipe x ½ ft. min. horizontal run

Part

number

N/A

Supplied by

Others

LP080 & aLP105

Horizontal (Snorkel)

Termination

2 1 N/A

4 2 N/A

N/A 2 4

2 1 N/A

N/A 1 2

Table 5: Clearances from Vent Piping to Combustible Material

Vent Pipe Pipe Direction Enclosure

CPVC/PVC Venting Vertical or Horizontal Enclosed at all Sides See Figures 2A and 2B

Table 6: Vent System and Combustion air System Components

LP150& aLP210

Horizontal (Snorkel)

Termination

Minimum Clearance To

Combustible Material

aLP285 thru aLP500

Horizontal (Snorkel)

Termination

Vent System Component Equivalent Length (Ft.)

Schedule 40 CPVC Pipe x 30 Inches 2.5 Schedule 80 CPVC 90° Elbow 5

WaRning

all condensate that forms in the vent must be able to drain back to the boiler.

Vent length restrictions are based on equivalent

length of vent/combustion air pipe (total length of straight pipe plus equivalent length of

ttings). Maximum vent/combustion air lengths

are listed in Table 7. Do not exceed maximum vent/combustion air lengths. Table 6 lists

equivalent lengths for ttings. Do not include

vent/combustion air terminals in equivalent feet calculations. See “Combustion Air/Vent, Equivalent Length Work Sheet”.

c. The vent termination location is restricted as per

'General Guidelines', Paragraph A, 5.

(Refer to Figure 3).

2. System Assembly a. Plan venting system to avoid possible contact

with plumbing or electrical wires. Start at vent connector at boiler and work towards vent termination.

b. Do not exceed maximum Vent/Combustion Air

length. Refer to Table 7.

Combustion Air

System Component

(Parts by Others)

Pipe x 1 Ft. 1 Pipe x 2 Ft. 2 Pipe x 4 Ft. 4 Pipe x 5 Ft. 5 Elbow 5 Elbow 2.5

*Equivalent Feet of Pipe Based on Standard 4” PVC Design

Equivalent

Feet of Pipe*

c. Design the Vent System to allow 3/8" of thermal

expansion per 10 feet of CPVC/PVC pipe. Runs of 20 feet or longer that restrained at both ends must use an offset or expansion loop. Refer to Figure 4.

Follow all manufacturer instructions and

warnings when preparing pipe ends for joining and using the primer and the cement.

3. Field Installation of CPVC/PVC Two-Pipe

Vent System Connector - Floor Mounted

Boiler Builds

Refer to Figure 5 and Steps below:

a. Position the CPVC/PVC vent connector and

gasket onto boiler rear/bottom panel and insert vent connector inner stainless steel vent pipe into heat exchanger vent outlet.

b. Align vent connector plate and gasket clearance

holes with rear/bottom panel engagement holes; than, secure the connector and gasket to the panel with six mounting screws.

iV. Venting (continued)

2 L

MIN

LONG RUN OF PIPE

CHANGE OF DIRECTION

(VERTICAL OR HORIZONTAL)

LOOP

(HORIZONTAL ONLY)

(TOP VIEW)

OFFSET

(L)

LOOP LENGTH

RESTRAINT (RESTRICTS MOVEMENT)

HANGER (ALLOWS MOVEMENT)

KEY

PIPE DIA.

(IN.)

LENGTH OF

STRAIGHT RUN

(FT.)

20 50 30 61 40 70 50 79 60 86 20 56 30 69 40 80 50 89 60 98

LOOP LENGTH

(L) (IN.)

Figure 4: Expansion Loop and Offset

Figure 5: Field installation of CPVC/PVC Two-Pipe Vent System Connector - Floor Mounted Boiler Builds

iV. Venting (continued)

Table 7: Vent/Combustion air Pipe Length – Two-Pipe Direct Vent System Options (CPVC/PVC and Stainless Steel/PVC or galvanized Steel)

Boiler Model

3” Combustion Air Pipe

(Equivalent Length)

Min. Max. Min. Max. Min. Max. Min. Max.

ALP080 30 In. 100 Ft. --- --- 30 In. 100 Ft. --- --ALP105 30 In. 100 Ft. --- --- 30 In. 100 Ft. --- --ALP150 --- --- 30 In. 100 Ft. 30 In. 100 Ft. --- --ALP210 --- --- 30 In. 100 Ft. 30 In. 100 Ft. --- --ALP285 --- --- 30 In. 60 Ft. --- --- 30 In. 60 Ft. ALP399 --- --- 30 In. 60 Ft. --- --- 30 In. 60 Ft. ALP500 --- --- 30 In. 60 Ft. --- --- 30 In. 60 Ft.

Vent/Combustion Air, Equivalent Length Work Sheet

This sheet is supplied to assist in vent/combustion air, equivalent length calculating

Combustion air Vent

90° elbow(s) PVC Supplied 30” straight CPVC Quantity = x 5 = equiv. ft. a. Length ft. = 2.5 x 1 = 2.5 equiv. ft. a.

4” Combustion Air Pipe

(Equivalent Length)

3” Vent Pipe

(Equivalent Length)

4” Vent Pipe

(Equivalent Length)

45° elbow(s) PVC Supplied 90° elbow CPVC

Quantity = x 2.5 = equiv. ft. b. Quantity = 1 x 5 = 5 equiv. ft. b.

Straight pipe PVC 90° elbow(s) PVC Length ft. = x 1 = equiv. ft. c. Quantity = x 5 = equiv. ft. c.

45° elbow(s) PVC

Quantity = x 2.5 = equiv. ft. d.

Straight pipe PVC Length ft. = x 1 = equiv. ft. e.

Total* a.+b.+c. = equiv. ft. Total* a.+b.+c.+d.+e.= equiv. ft.

* Total cannot exceed 60 equiv. ft. length. Vent and combustion air terminals do not count towards total equiv. ft.

Figure 6a: near-Boiler Vent/Combustion air Piping - Floor Mounted Boiler Builds

iV. Venting (continued)

4. Near-Boiler Vent/Combustion Air Piping

- Floor Mounted Boiler Builds

Refer to Figure 6A and the following Steps:

a. All CPVC vent components supplied with boiler

inside vent carton (3” or 4” Schedule 40 x 30” long CPVC pipe and 3” or 4” Schedule 80 CPVC 90° Elbow) must be used for near-boiler piping before transitioning to Schedule 40 PVC (ASTM

2665) pipe components for reminder of vent system. The CPVC 30” long straight pipe may be

cut to accommodate desired vent conguration

provided both pieces are used in conjunction with CPVC 90° Elbow before any PVC components are used. Ensure that the CPVC 90°

Elbow is the rst elbow used in the vent system

as it exits the boiler.

b. Clean all vent and combustion air pipe joints

with primer and secure with transition cement (4-oz. bottles of primer and cement are supplied with boiler inside vent carton). Follow application instructions provided on primer and

cement bottles.

5. Field Installation of CPVC

Mounted Boiler Builds

Refer to Figure 6B and the following Steps: The wall mounted boiler builds do not require using

3” Schedule 80 CPVC 90° Elbow for near-boiler vent piping.

a. Insert provided 3” Schedule 40 x 30” long

CPVC pipe thru air box top combination vent/ combustion air collar vent opening and slide down with a slight twisting motion, until the pipe

lower end is rmly inserted into female end of

factory installed vent connector 90° Elbow.

Secure the pipe by tightening the metal strap

worm screw. i. The CPVC 30” long straight pipe may be cut

to accommodate desired vent conguration.

If the CPVC 30” straight pipe needs to be

cut into two pieces to accommodate desired

vent conguration, insure that the rst

vertical piece has minimum length of 12 inches and extends 1-5/8” above air box top, so a coupling or an elbow can be attached to it.

ii. The factory supplied CPVC vent pipe

(3” Schedule 40 x 30” long CPVC pipe) must be used for near-boiler piping before transitioning to Schedule 40 PVC (ASTM

2665) pipe components for reminder of vent system.

iii. Clean all vent and combustion air pipe

joints with primer and secure with transition

Vent Pipe - Wall

Figure 6B: Field

Figure 7: CPVC/PVC Vent Pipe

Thru Combustible Wall installation

6. Horizontal Vent Termination

a. Standard Two-Pipe Termination See Figures 7 through 10.

i. Vent Piping

installation of CPVC Vent Pipe -

Wall Mounted Boiler Builds

cement (4-oz. bottles of primer and cement are supplied with boiler). Follow application instructions provided on primer and cement

bottles.

• When conditions in Figure 7 cannot be met, use a single wall thimble [(US boiler part number 102180-01 (3”) or 102181-01 (4”)] for vent only, when penetrating a combustible wall. Thimble

iV. Venting (continued)

Figure 8 : Direct Vent - Sidewall Terminations

use is optional for non-combustible wall. Insert thimble from wall from outside.

Secure outside ange to wall with nails

or screws, and seal ID, OD and vent holes with sealant material. Install inside

ange to inside wall, secure with nails or

screws, and seal with sealant material.

• For noncombustible wall application when thimble is not used, size opening such that a minimal clearance is obtained.

See Figure 7.

• Install Rodent Screen and Vent Terminal (supplied with boiler), see Figure 9 for

appropriate conguration.

• Apply sealant between vent pipe and opening/thimble to provide weather-tight seal. Sealant should not restrain the expansion of the vent pipe.

ii. Combustion

• Do not exceed maximum combustion air length. Refer to Table 7.

Size combustion air wall penetration to

• allow easy insertion of combustion air piping.

•

Install Rodent Screen and Combustion

Air Terminal (supplied with boiler), see

Figure 9 for appropriate conguration.

Apply sealant between vent pipe and

• opening to provide weather-tight seal.

Optional Two-Pipe Snorkel Termination Refer to Figures 7, 9 and 10. This installation will allow a maximum of

seven (7) feet vertical exterior run of the vent/ combustion air piping to be installed on the CPVC/PVC horizontal venting application.

Air Piping

nOTiCE

Exterior run to be included in equivalent vent/

combustion air lengths.

ent Piping

i. V

• After penetrating wall, install a Schedule 40 PVC 90° elbow so that the elbow leg is in the up direction.

• Install maximum vertical run of seven (7) feet of Schedule 40 PVC vent pipe. See Figure 10.

• At top of vent pipe length install another PVC 90° elbow so that elbow leg is opposite the building’s exterior surface.

• Install Rodent Screen and Vent Terminal (supplied with boiler), see Figure 9 for

appropriate conguration.

• Brace exterior piping if required.

ii. Combustion Air Piping

• After penetrating wall, install a Schedule 40 PVC 90o elbow so that elbow leg is in the up direction.

Figure 9: Rodent Screen installation

iV. Venting (continued)

Figure 10: Direct Vent - Optional Sidewall

Snorkel Terminations

• Install maximum vertical run of seven (7) feet of Schedule 40 PVC vent pipe. See Figure 10.

• At top of vent pipe length install another PVC 90° elbow so that elbow leg is opposite the building’s exterior surface.

• Install Rodent Screen and Combustion Air Terminal (supplied with boiler), see

Figure 9 for appropriate conguration.

• Brace exterior piping if required.

WaRning

all CPVC supplied with the vent kit must be used prior to connection of the vent system to this terminal. if the vent system is too short to permit this, do not use this terminal.

Do not operate boiler without the rain cap in place.

Methods of securing and sealing terminals to the outside wall must not restrain the thermal expansion of the vent pipe.

Vertical Vent Termination

7. a. Standard Two-Pipe Termination

Refer to Figures 7, 9, 11 and 12.

Figure 11: Direct Vent - Vertical Terminations

ent Piping

i. V

• Install re stops where vent passes through oors, ceilings or framed walls. The re stop must close the opening

between the vent pipe and the structure.

• Whenever possible, install vent straight through the roof. Refer to Figures 11 and

12.

- Size roof opening to maintain

minimum clearance of 1" from combustible materials.

Extend vent pipe to maintain minimum

vertical and horizontal distance of twelve (12) inches from roof surface. additional vertical distance for expected snow accumulation. Provide brace as required.

CaUTiOn

Vertical venting and combustion air roof

penetrations (where applicable) require the use of roof ashing and storm collar, which are not

supplied with boiler, to prevent moisture from entering the structure.

- Install storm collar on vent pipe

immediately above ashing. Apply

Dow Corning Silastic 732 RTV Sealant between vent pipe and storm collar to provide weather-tight seal.

iV. Venting (continued)

Figure 12: Direct Vent - Vertical Terminations

with Sloped Roof

Extend vent/combustion air piping to maintain minimum vertical (‘X’) and minimum horizontal (‘Y’) distance of twelve (12) inches (18 inches Canada) from roof surface. a snow accumulation.

llow additional vertical (‘X’) distance for expected

• Install Rodent Screen and Vent Terminal (supplied with boiler), see Figure 9 for

appropriate conguration.

• Brace exterior piping if required.

ii. Combustion Air Piping

• Locate combustion air termination on the same roof location as the vent termination to prevent nuisance boiler shutdowns. Combustion air terminal can be installed closer to roof than vent.

• Size roof opening to allow easy insertion of combustion air piping and allow

proper installation of ashing and storm

collar to prevent moisture from entering the structure.

- Use appropriately designed vent

ashing when passing through roofs. Follow ashing manufacturers’

instructions for installation procedures.

- Extend combustion air pipe to

maintain minimum vertical and horizontal distance of twelve (12) inches from roof surface. Allow additional vertical distance for expected snow accumulation. Provide brace as required.

- Install storm collar on combustion

air pipe immediately above ashing.

Apply Dow Corning Silastic 732 RTV Sealant between combustion air pipe and storm collar to provide weather-tight seal.

• Install Rodent Screen and Combustion Air Terminal (supplied with boiler), see

Figure 9 for appropriate conguration.

• Brace exterior piping if required.

WaRning

all CPVC supplied with the vent kit must be used prior to connection of the vent system to this terminal. if the vent system is too short to permit this, do not use this terminal.

Do not operate boiler without the rain cap in place.

Methods of securing and sealing terminals to the outside wall must not restrain the thermal expansion of the vent pipe.

iV. Venting (continued)

C. Stainless Steel Venting

CaUTiOn

Vent systems made by Heat Fab, Protech and Z-Flex rely on gaskets or proper sealing. When these vent systems are used, take the following precautions:

• Make sure that gasket is in position and un damaged in the female end of the pipe.

• Make sure that both the male and female pipes are free of damage prior to assembly.

• Only cut vent pipe as permitted by the vent manufacturer in accordance with their in structions. When pipe is cut, cut end must

be square and carefully de-burred prior to

assembly.

WaRning

all condensate that forms in the vent must be able to drain back to the boiler.

Vent Length Restrictions

a. Vent length restrictions are based on equivalent

length of vent/combustion air pipe (total length of straight pipe plus equivalent length of

ttings). Maximum vent/combustion air lengths

are listed in Table 7. Do not exceed maximum vent/combustion air lengths. Do not include vent/combustion air terminals in equivalent feet calculations. See “Combustion Air/Vent, Equivalent Length Work Sheet”.

b. The vent termination location is restricted as

per 'General Guidelines', Section A.5. (Refer to Figure 3)

c. Where the use of “silicone” is called for in the

following instructions, use GE RTV 106 or equivalent for the vent collar. Air inlet piping sections are sealed with any general-purpose silicone sealant such as GE RTV102. PVC air inlet piping sections are connected with PVC cement.

d. Longitudinal welded seams should not be placed

at the bottom of horizontal sections of exhaust

pipe. e. Do not drill holes in vent pipe. f. Do not attempt to mix vent components of

different vent system manufacturers.

2. Near Boiler Connection

To install the stainless steel vent adapter

[P/N 102219-01 (3”). 102220-01 (4”)]:

a. Push the stainless steel vent adapter onto the

CPVC/PVC connector with a slight twisting motion. Make sure that the stainless steel vent adapter is inserted at least 1” (refer to Figure 13).

Figure 13: Field installation of Two-Pipe Vent

System adapter for Stainless Steel

b. Secure the adapter to the CPVC/PVC connector

by tightening the metal strap.

3. System Assembly a. Plan venting system to avoid possible contact

with plumbing or electrical wires. Start at vent connector at boiler and work towards vent termination.

b. Refer to Tables 8A and 8B for approved AL29C

Vent Systems.

c. Do not exceed maximum Vent/Combustion air

length. Refer to Table 7.

d. Follow all manufacturer instructions and

warnings when preparing pipe ends for joining and using the primer and the cement.

e. Assemble the air intake system using either

galvanized or PVC pipe. i. If PVC piping is used, use PVC cement

to assemble the PVC intake system components. See Part B for air intake installation instructions.

ii. If galvanized piping is used, use at least two

sheet metal screws per joint. Seal the outside of all joints.

4. Horizontal Vent Termination a. Standard Two-Pipe Termination

Refer to Figure 8.

i. Vent Termination

• Use U.S. Boiler stainless exhaust terminal [P/N 8110701 (3”), or P/N 100184-01 (4”)]. The outer edge of this terminal must be between 6" and 12" from the surface of the wall.

The joint between the terminal and

the last piece of pipe must be outside of the building.

iV. Venting (continued)

• Male end of terminal will t into the

female end of any of the approved stainless vent systems.

Apply a heavy bead of silicone to the

• male end of the terminal before inserting it into the last piece of pipe. Orient the terminal so that the seam in the terminal is at 12:00.

• Smooth the silicone over the seam between the terminal and the last piece of pipe, applying additional silicone if necessary to ensure a tight seal.

• Allow the silicone to cure per the silicone manufacturer’s instructions before operating the boiler.

Table 8a: U.S. Boiler Vent System Components

(Stainless Steel)

Vent System

Component

SS Vent Kit 102501-01 102501-02 Horizontal Vent

Terminal

(Included in Kit)

PVC to SS Vent Adapter

(Included In Kit) Vertical Vent Terminal 102680-01 102680-02 N/A

Pipe x 1 Ft. 8116296U 100176-01 1 Pipe x 3 Ft. 8116298U 100177-01 3 Pipe x 5 Ft. 8116300U 100178-01 5

Pipe x Adjustable 8116319U 100179-01

90° Elbow 8116294U 100180-01

45° Elbow 8116292U 100181-01 Horizontal Drain Tee 8116302U 100182-01 2

Vertical Drain Tee 8116304U 100183-01 7½

Single Wall Thimble 8116116 100184-01 N/A

Part Numbers

ALP080 - 210 ALP285 - 500

3" Vent 4" Vent

8116310 8116313

102219-01 102220-01

Equivalent

Feet of Pipe

N/A

Equal to

Installed

Length

(1.06 to 1.64)

5.5 (3")

8.0 (4")

4.0 (3")

4.5 (4")

ii. Combustion

Air Termination

• Horizontal intake terminal is a tee in the upright position. Tee should protrude the same distance from the wall as the exhaust terminal. See Figure 8.

• Install a rodent screen (not supplied) in the inlet terminal. Use a screen having 1/2”

(2 x 2) or larger mesh.

b. Optional Two-Pipe Snorkel Termination Refer to Figure 10.

This installation will allow a maximum of

seven (7) feet vertical exterior run of the vent/ combustion air piping to be installed on the approved AL29C Stainless Steel horizontal venting application.

i. Vent Termination

• After penetrating wall, install the

appropriate manufacturer's 90° elbow so that the elbow leg is in the up direction.

• Install maximum vertical run of seven

(7) feet of appropriate manufacturer's vent pipe. See Figure 10.

• At top of vent pipe length install another

appropriate manufacturer's 90° elbow so that the elbow leg is opposite the building's exterior surface.

• Install horizontal vent terminal.

• Brace exterior piping if required.

ii. Combustion

Air Termination

• After penetrating wall, install a 90° elbow so that the elbow leg is in the up direction.

Install maximum vertical run of seven

• (7) feet of combustion air pipe. See Figure 10.

• At top of vent pipe length install another 90° elbow os that the elbow leg is opposite the building's exterior surface.

Table 8B: alternate Vent Systems and Vent Components (Stainless Steel)

Manufacturer

Protech

Systems

Inc..

Z-Flex

Flex-L Intl. Star-34

Vent

System

FasNseal

SVE

Series III

(“Z-Vent III”)

Size Wall Thimbles Horizontal Termination

3 FSWT3 Tee: FSTT3 FSBS3 4 FSWT4 Tee: FSTT4 FSBS4

3 2SVSWTEF03 Tee: 2SVSTTF03 24SVSTPF03 4 2SVSWTEF04 Tee: 2SVSTTF04 24SVSTPF04

3 SR03WT15 Tee: SRTT-03 SRTP-03 4 SR04WT15 Tee: SRTT-04 SRTP-04

NOTE: See vent system manufacturer’s literature for other part numbers that are required such as straight pipe, elbows, restops

and vent supports.

Vertical

Termination

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