Energy Star ALPINE, ALP080B, ALP105B, ALP150B, ALP210B Installation, Operating And Service Instructions

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Page 1

DNAGNITAREPO,NOITALLATSNI

ROFSNOITCURTSNIECIVRES

™ENIPLA

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RELIOBRETAWTOHDERIF-SAG

9700609

As an ENERGY STAR

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

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.

103448-02 - 6/13 Price - $5.00

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

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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.

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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.

2. 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.

C. 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:

1. 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.

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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, or service. Installation and service must be performed only by an experienced, skilled, and 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 safety relief valve is installed into the tapping located on left side of boiler. - 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 service. If damage due to frozen pipes is a possibility, the heating system should not be left unattended in cold weather; or appropriate safeguards and alarms should be installed on the heating system to prevent damage if the boiler is inoperative.

This boiler contains very hot water under 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 boiler.

Failure to follow all instructions in the proper order can cause personal injury or death. Read all instructions, including all those contained in component manufacturers manuals which are provided with the boiler before installing, starting up, operating, maintaining or servicing.

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

NOTICE

This boiler has a limited warranty, a copy of which is included with this boiler. 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.

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TABLE OF CONTENTS

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

II. Unpacking Boiler........................................................................................ 11

III. Pre-Installation and Boiler Mounting ........................................................ 12

IV. Venting...................................................................................................... 19

A. General Guidelines............................................................................... 19

B. CPVC/PVC Venting.............................................................................. 22

C. Polypropylene Venting......................................................................... 31

D. Stainless Steel Venting........................................................................ 37

E. Concentric Polypropylene Venting....................................................... 39

F. Removing the Existing Boiler............................................................... 44

G. Multiple Boiler Installation Venting....................................................... 46

V. Condensate Disposal................................................................................. 50

VI. Water Piping and Trim............................................................................... 52

VII. Gas Piping ............................................................................................... 67

VIII. Electrical ................................................................................................... 71

IX. System Start-up ....................................................................................... 83

X. Operation...................................................................................................... 91

A. Overview............................................................................................... 91

B. Supply Water Temperature Regulation................................................ 92

C. Boiler Protection Features.................................................................... 93

D. Multiple Boiler Control Sequencer........................................................ 94

E. Boiler Sequence of Operation.............................................................. 95

1. Normal Operation........................................................................... 95

2. Using The Display.......................................................................... 96

F. Viewing Boiler Status............................................................................ 97

1. Status Screens.............................................................................. 97

2. Detail Screens............................................................................... 98

3. Multiple Boiler Sequencer Screens................................................ 99

G. Changing Adjustable Parameters........................................................ 100

1. Entering Adjust Mode.................................................................... 100

2. Adjusting Parameters..................................................................... 100

XI. Service and Maintenance ........................................................................ 111

XII. Troubleshooting........................................................................................ 115

XIII. Repair Parts ............................................................................................. 119

Appendix A - Figures................................................................................ 131

Appendix B - Tables.................................................................................. 134

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I. Product Description, Specications and Dimensional Data

Alpine™ Series boilers are condensing high efciency gas-red direct vent hot water heating 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 ‘Rules

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

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) - Inch

Boiler

CPVC Vent Connector/Pipe

(Fig. 1B) - Inch

Boiler Inlet Air Connector

(Fig. 1B) - Inch

Approx. Shipping Weight

(LBS)

ALP080B

12-9/16

9-5/16

(1)

ALP105B

(320)

(356)

5-5/8

(142)

10-3/4

(237)

(273)

* 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

137 155 182 206 256 304

for Construction of Heating Boilers’ of 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)

ALP150B

19-11/16

5-13/16

7-5/16

(186)

16-7/16

5-15/16

(151)

1/2” 3/4” 3/4”

1” 1-1/4” 1-1/2”

for 3/4” Schedule 40 PVC Pipe

3” N/A N/A

(500)

(147)

(417)

(1)

ALP210B

23-15/16

(608)

17-1/8

(435)

(1)

ALP285B

21-13/16

(554)

7-5/16

(185)

14-1/8

(358)

(456)

12-1/4

(312)

(2)

ALP399

15-13/16

(2)

28-7/8

(734)

6-3/16

(157)

13-1/16

(332)

23-3/4

(602)

(402)

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.

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

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Figure 1A: Alpine™ - Models ALP080B thru ALP210B (Floor Mounted)

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

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Figure 1B: Alpine™ - Models ALP080B thru ALP210B (Wall Mounted)

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

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Figure 1C: Alpine™ - Models ALP285B thru ALP399 (Floor Mounted Only)

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

Table 2A: Rating Data - Models ALP080B thru ALP399 (0 to 2000 Feet Elevation Above Sea Level)

Alpine Series Gas-Fired Boilers

* Model Number

ALP080B 16 80 0.6 7.3

ALP105B 21 105 0.7 9.1

ALP150B 30 150 1.3 16.4

ALP210B 42 210 1.7 21.8

ALP285B 57 285 2.4 29.1

ALP399 80 399 3.4 41.8

* Add Sufx “F” for Floor mounted Models or Sufx “W” for Wall mounted Models.

Notes: Maximum Working Pressure, Water - 30 PSI Shipped from Factory (std.); 50 PSI, 80 PSI and 100 PSI - Optional (ALP080B thru ALP285B) Maximum Working Pressure, Water - 50 PSI Shipped from Factory (std.); 80 PSI and 100 PSI - Optional (ALP399 only) 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 the Installation, Operating and Service Instructions 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.

Input (MBH)

Min. Max.

Boiler Water

Volume (Gal.)

Heat Transfer Area

(Sq. Ft.)

Table 2B: Rating Data - Models ALP080B thru ALP399 (2001 to 7000 Feet Elevation Above Sea Level)

Alpine Series Gas-Fired Boilers

Model Number *

ALP080B 27 80 0.6 7.3

ALP105B 35 105 0.7 9.1

ALP150B 50 150 1.3 16.4

ALP210B 70 210 1.7 21.8

ALP285B 57 285 2.4 29.1

ALP399 80 399 3.4 41.8

* Add Sufx “F” for Floor mounted Models or Sufx “W” for Wall mounted Models.

Notes: 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 only) 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 the Installation, Operating and Service Instructions 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 (MBH)

Min. Max.

Boiler Water

Volume (Gal.)

Heat Transfer Area

(Sq. Ft.)

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

Table 2C: Rating Data - Models ALP150B thru ALP285B (7001 to 10,000 Feet Elevation Above Sea Level)

Alpine Series Gas-Fired Boilers

Model Number *

ALP150B 38 113 1.3 16.4

ALP210B 53 158 1.7 21.8

ALP285B 68 204 2.4 29.1

* Add Sufx “F” for Floor mounted Models or Sufx “W” for Wall mounted Models.

Notes: 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.

More detailed boiler ratings can be found at U.S. Boiler’s web site (www.usboiler.net)

Input (MBH)

Min. Max.

Boiler Water

Volume (Gal.)

Heat Transfer Area

(Sq. Ft.)

II. Unpacking Boiler

CAUTION

Do not drop boiler.

A. Move boiler to approximate installed position.

B. Remove all crate fasteners.

C. Lift and remove outside container.

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D. Remove boiler from cardboard positioning sleeve on

shipping skid.

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.

Page 12

III. Pre-Installation and 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 Company DOES NOT warrant failures caused by mis-sized boiler applications. DO NOT oversize the boiler to the system. Multiple 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 Natural Gas and Propane Installation Code.

B. Boiler 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

Adequate combustion and ventilation air must

be provided to assure proper combustion.

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

length of the vent system. The 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 (ALP080B thru ALP399, or, as wall hung (ALP080B thru ALP210B). Factory assembled

oor standing models are identied with sufx F in

a boiler part number code (example – ALP210BF1L02). Factory assembled wall hung models are

identied with sufx W in a boiler part number code

(example – ALP210BW-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.

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Page 13

III. Pre-Installation and Boiler Mounting G. General (continued)

c. Provide adequate space for condensate piping or

a condensate pump if required.

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:

ALP080BW – 98 lbs; ALP105BW – 112 lbs;

ALP150BW – 136 lbs: ALP210BW – 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 requirements for supporting these boilers. Such local requirements take precedence over the requirements shown below.

b. 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.

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

are intended for mounting the boiler directly onto studs covered with ½” drywall. 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 102981-01

(ALP080BW/105BW) or P/N 102981-02

(ALP150BW/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.

i. 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.

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III. Pre-Installation and Boiler Mounting G. General (continued)

Figure 2A: Clearances To Combustible and Non-combustible Material, Floor Standing

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

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Page 15

III. Pre-Installation and Boiler Mounting G. General (continued)

m. See Section IV Venting; Paragraph B, 5 “Field

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

WARNING

Vent pipe must be inserted rmly into vent

connector and secured by tightening the metal strap worm screw.

WALL MOUNTING BRACKET

CENTER LINE

1.0" MIN. CLEARANCE TO COMBUSTIBLE

TOP EDGE OF BOILER

'HOLE B'

" DIA. PILOT HOLES

FOR

" LAG SCREWS

(4 PLACES)

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

to vent and combustion air system piping and combustion performance testing completed per Section IX “System Start-up”, install Access Panel/Gasket assembly and secure with provided four #8 x ½” black oxide Phillips head sheet metal screws. See Figure 2E “access Panel and Gasket Installation”.

WARNING

Access Panel must be installed while boiler is in operation.

2.0" MIN. CLEARANCE TO COMBUSTIBLE

'HOLE A'

10.0" MIN. CLEARANCE TO COMBUSTIBLES

BOTTOM SECURING

BRACKET CENTER LINE

LEFT SIDE OF BOILER

'HOLE C'

'HOLE D'

Figure 2C: Wall Mounting Hole Location / Layout

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Page 16

III. Pre-Installation and Boiler Mounting G. General (continued)

16" C/C

2 X 4

WALL STUD

1 2

" SHEET

ROCK

WALL BRACKET

1 2

#8 X

BOTTOM SECURING BRACKET

" SMS (2X)

BOTTOM SECURING BRACKET

" X 2" FLAT

WASHER (4X)

BOILER HANGING BRACKET

BOILER

" X 2" LAG

SCREW (4X)

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

BOILER HANGING BRACKET

BOILER

Figure 2E: Access Panel and Gasket Installation

16 103448-02 - 6/13

Page 17

III. Pre-Installation and Boiler Mounting H. Boiler Stacking (continued)

H. Boiler Stacking

1. For installations with unusually high space heating and/or domestic hot water heating loads, where employing two (2) Alpine (ALP) boilers will offer

the benets of greater operational efciency, oor

space savings and boiler redundancy, the Alpine (ALP) boilers may be installed stacked one on the top of the other. Refer to Table 3 “Alpine (ALP) Boiler Model Stacking Combinations” for details.

Table 3: Alpine (ALP) Boiler Model Stacking Combinations

Bottom

Boiler Model

ALP080B

ALP105B ALP150B ALP210B

ALP285B ALP080B, ALP105B, ALP150B & ALP285B

ALP399 ALP080B thru ALP399

Notes:

(2)

(1)

Floor-mounted builds only Floor-mounted or wall-mounted build where applicable

Top Boiler Model

ALP080B

ALP080B or ALP105B ALP080B thru ALP150B ALP080B thru ALP210B

2. To eld assemble individual Alpine (ALP) boilers into a stackable conguration, use the steps below:

a. Position the bottom boiler rst. Refer to Sections

II “Unpacking Boiler” and III “Pre-Installation & Boiler Mounting” of the manual for details.

Always position higher input boiler model as

bottom boiler.

b. Each Alpine (ALP) boiler is factory packaged

with two (2) Stacking Boiler Attachment Brackets (P/N 101679-01) and the bracket mounting hardware [six (6) self-drilling hex washer head plated #8 x ½” long screws, P/N 80860743]. Locate and remove the brackets and the hardware. The Stacking Boiler Attachments Bracket has three 7/32” diameter holes punched in a triangular pattern. See Figure 3 “Stacking Boiler Attachment Bracket Placement”.

c. Alpine (ALP) 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 screws. Side panel bottom positioning dimples are evenly spaced from boiler front and back, while side panel top positioning dimples follow

specic pattern to compensate for Alpine (ALP)

boiler model variable depth.

d. Position the upper boiler on the top of the bottom

boiler and align boiler front doors and sides ush

with each other.

• Place rst Stacking Boiler Attachment

Bracket onto the upper boiler left side panel, at the panel lower left corner and align

(2)

bracket two upper holes with corresponding side panel lower dimples.

• The remaining lower bracket hole must align

with a matching bottom boiler left side panel top positioning dimple.

• Once bracket holes and side panel dimple alignment is veried, attach the bracket to

top and bottom boiler left side panels with the mounting screws.

e. Repeat above procedure to install second

Stacking Boiler Attachment Bracket and secure the stacked boiler right side panels together at the front right corner.

f. Install the third Stacking Boiler Attachment

Bracket to secure top and bottom boiler left side panels at the rear left corner. Align the bracket holes with corresponding positioning dimples in the top boiler and bottom boiler left side panels, then secure bracket with the screws.

g. Repeat above procedure to install the forth

Stacking Boiler Attachment Bracket to secure stacked boiler right side panels at the rear right corner.

3. When installing stackable boiler combinations observe the following guidelines:

a. Venting - Top and bottom boilers must have their

individual vent piping and vent terminals.

WARNING

No common manifolded venting is permitted.

For side-wall venting individual model vent

terminals must terminate not closer than 12 inches horizontally and three (3) feet vertically from each other in order to prevent combustion air contamination. For vertical through the roof venting, individual vertical vent terminals, if level with each other, must be spaced no closer than 12 inches horizontally. If vertical terminals cannot end in one plane, they must be spaced no closer than three (3) feet horizontally.

Chimney chase concentric venting is permitted

for modules, when stackable, providing concentric vertical (roof) vent terminals, if level with each other, are spaced no closer then 12 inches horizontally.

If vertical vent terminals cannot end in one

plane, they must be spaced no closer then three (3) feet horizontally.

Follow instructions in Section IV “Venting”

of the manual for specics of individual boiler

vent termination. Follow instructions in Section V “Condensate Disposal” for each individual

boiler ue gas condensate line construction and

103448-02 - 6/13 17

Page 18

III. Pre-Installation and Boiler Mounting H. Boiler Stacking (continued)

condensate disposal. Terminating individual boiler condensate lines into common pipe prior to drain disposal is permissible, providing

common pipe has sufcient ow capacity

to handle combined condensate volume of stackable combination.

b. Gas Piping - Follow instructions in Section

VII “Gas Piping” of the manual for sizing and installation of an individual boiler. When common gas piping is sized, insure it will have

adequate capacity for combined input (CFH gas ow) of the selected stackable boiler

combination.

c. Water Piping and Trim - Follow instructions

in Section VI “Water Piping and Trim” of the manual for system piping and boiler secondary piping selection/sizing based on combined

heating capacity and/or gross output of

the selected stackable boiler combination. Follow instructions of Section VI “Water Piping and Trim” for each individual boiler trim installation.

d. Electrical - Follow instructions in Section VIII

“Electrical” of the manual to wire individual boilers.

Figure 3: Stacking Boiler Attachment Bracket Placement

18 103448-02 - 6/13

Page 19

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 vent 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 B149.1.S1-07 and are not ap-

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 Gas vent or a listed ULC S636 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), cellular core CPVC or Radel (polyphenolsulfone) is prohibited.

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 4):

a. 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.

b. Two-Pipe Polypropylene Vent/Combustion Air

System - separate rigid or exible polypropylene

pipe serves to expel products of combustion and separate rigid polypropylene pipe or PVC pipe delivers fresh outdoor combustion air. Refer to

part C for specic details.

103448-02 - 6/13 19

c. 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.

d. 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.

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

a. Vent terminals must be at least 1 foot from door,

window, or gravity inlet into the building.

Page 20

IV. Venting A. General Guidelines (continued)

Table 4: Vent/Combustion Air System Options

Approved Direct

Vent System

Factory Standard

Two-Pipe,

CPVC/PVC

Vent and PVC

Air Intake

Available Optional

Two-Pipe, Rigid

Polypropylene

Vent (or Flexible

Polypropylene Liner

for Vertical venting

only) and Rigid

Polypropylene or PVC

Pipe Air Intake

Available Optional

Two-Pipe,

Stainless Steel Vent

and PVC/Galvanized

Steel Air Intake

Available Optional

Concentric, Inner

Polypropylene Vent and Outer Steel Air

Intake

Boiler

Mounting

Floor Standing

or Wall Hung

Installations

Floor Standing

or Wall Hung

Installations

Floor Standing

Installations

Only

Floor Standing

Installations

Only

Vent

Material

CPVC/PVC

Rigid

Polypropylene

(or Flexible

Polypropylene

Liner for

vertical

Venting only)

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 Rigid Polypropylene vent pipe and Rigid Polypropylene or 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 Flexible Polypropylene vent liner and Rigid Polypropylene vent pipe combination for venting and Rigid Polypropylene or PVC air intake pipe terminating thru roof with individual penetrations for the vent and air intake and individual vent /air

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.

5 thru 10 5A

5, 6A, 6B,

7, 8, 10,

4, 5A, 5B,

6, 9, 11

6, 7A, 7B, 9, 9A, 9B, 10, 14, 15

11, 14, 15 9, 10

12, 13, 14,

15, 16

9, 17

11, 17

12, 13, 17

18 thru 25

18, 19, 20, 21,

26 thru 30

Horizontal

Optional

Vertical

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 or chimney/

chase)

Standard

(thru sidewall)

Optional

Snorkel

(thru sidewall)

Vertical

(thru roof)

Horizontal

(Wall) Terminal

Vertical (Roof)

Terminal

Component

Table

9, 10

13A, 13B D.

14, 15 E.

Part

20 103448-02 - 6/13

Page 21

IV. Venting A. General Guidelines (continued)

Figure 4: 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)

b. Maintain the correct clearance and orientation

between the vent and air intake terminals. i. The centerlines between the vent and air

intake terminals must be spaced a minimum of 12” apart. More than 12” spacing is recommended.

ii. If possible, locate air intake and vent

terminations on the same wall to prevent nuisance shutdowns. However, boiler may be installed with vertical venting and sidewall combustion air inlet or vice versa where installation conditions do not allow for alternate arrangement.

iii. The vent and air intake terminations may be

at varying heights when installed on the same wall, but the height of the vent termination should always be higher than the air intake

termination and within the specied limit as

shown in Figure 9B.

c. 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.

d. The bottom of the vent terminal must be at least 7

feet above a public walkway.

e. Do not install the vent terminal directly over

windows or doors.

f. The bottom of the vent terminal must be at least

3 feet above any forced air inlet located within 10 feet.

g. 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.

h. Do not locate the vent terminal under decks or

similar structures.

i 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.

j. Top of vent terminal must be at least 5 feet below

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

overhang is 3 ft.

k. 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.

l. Concentric - Minimum twelve (12) inches

horizontally from a building corner.

m. 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.

103448-02 - 6/13 21

Page 22

IV. Venting A. General Guidelines (continued)

B. CPVC/PVC Venting

n. 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.

o. Air intake terminal must not terminate in areas that

might contain combustion air contaminates, such as near swimming pools.

p. 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.

q. The minimum horizontal distance between any

adjacent individual module (boiler) roof vent terminations is one (1) foot.

7. Use noncombustible ¾" pipe strap to support 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.

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.

WARNING

When using the CPVC/PVC vent options, the use

of CPVC is required when venting in vertical or

horizontal chase ways.

1. Components and Length Restrictions

a. See Table 5A for CPVC/PVC Vent & Air Intake

Components included with boiler, Table 5B for CPVC/PVC Vent and Air Intake Components (Installer Provided) required for Optional Horizontal (Snorkel) Termination and Table 5C for CPVC/PVC Vent and Air Intake Components (Installer Provided) required for Optional Vertical (Roof) Termination.

WARNING

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

b. 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 8. 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, 6.

(Refer to Figure 4).

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 8.

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 5 and Table 7.

22 103448-02 - 6/13

Page 23

IV. Venting B. CPVC/PVC Venting (continued)

d. 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 6 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

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.

c. Apply supplied dielectric grease (grease pouch

attached to two-pipe vent connector) to gasket inside vent section of two-pipe vent connector, The grease will prevent gasket rupture when inserting vent pipe and gasket deterioration due to condensate exposure.

heat exchanger vent outlet.

Table 5A: CPVC/PVC Vent & Air Intake Components Included With Boiler

Quantity

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

Number

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

ALP080B & ALP105B

Standard Termination

Vent Kit

(P/N 102189-01)

includes

ALP150B & ALP210B

Standard Termination

Vent Kit

(P/N 102189-02)

includes

ALP285B thru

ALP399 Standard

Termination Vent Kit

(P/N 102189-03)

includes

Table 5B: CPVC/PVC Vent & Air Intake Components (Installer Provided) required for Optional Horizontal

(Snorkel) Termination

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 2 N/A

4" Schedule 40 PVC 90° Elbow N/A 2 4

3" Schedule 40 PVC Pipe x ½ ft. min. horizontal run 2 1 N/A

4" Schedule 40 PVC Pipe x ½ ft. min. horizontal run N/A 1 2

103448-02 - 6/13 23

Part

Number

N/A

Supplied

Others

ALP080B &

ALP105B

Horizontal (Snorkel)

Termination

2 1 N/A

Quantity

ALP150B &

ALP210B

Horizontal (Snorkel)

Termination

ALP285B thru

ALP399

Horizontal (Snorkel)

Termination

Page 24

IV. Venting B. CPVC/PVC Venting (continued)

Table 5C: CPVC/PVC Vent & Air Intake Components (Installer Provided) required for Optional Vertical

(Roof) Termination

Quantity

Vent Components

3" Schedule 40 PVC Coupler 4" Schedule 40 PVC Coupler N/A 1 1 3" Schedule 40 PVC 90° Elbow 2 N/A N/A

4" Schedule 40 PVC 90° Elbow N/A 2 2

3" Schedule 40 CPVC Pipe x ½ ft. min. horizontal run 1 N/A N/A 4" Schedule 40 CPVC Pipe x ½ ft. min. horizontal run N/A 1 1

Part

Number

N/A

Supplied

by Others

ALP080B &

ALP105B

Vertical (Roof)

Termination

1 N/A N/A

Table 6: Vent System and Combustion Air System Components Equivalent Length

vs. Component Nominal Diameter

Vent or Combustion Air System

Component Description

Component Nominal Diameter, In. 3” 4”

90° Elbow (Sch. 80 or Sch. 40) 10 13

45° Elbow (Sch. 80 or Sch. 40) 3 4.5

Sch. 40 CPVC Pipe x 30 In. Long 2.5

Sch. 40 PVC Pipe x 1 Ft. Long 1

Sch. 40 PVC Pipe x 2 Ft. Long 2

Sch. 40 PVC Pipe x 3 Ft. Long 3

Sch. 40 PVC Pipe x 4 Ft. Long 4

Sch. 40 PVC Pipe x 5 Ft. Long 5

Equivalent Length (Ft.) for Vent or Combustion Air System Component

vs. Component Nominal Diameter (In.)

ALP150B &

ALP210B

Vertical (Roof)

Termination

ALP285B thru

ALP399

Vertical (Roof)

Termination

4. Near-Boiler Vent/Combustion Air Piping -

Floor Mounted Boiler Builds

Refer to Figure 7A 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.

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.

b. Secure the pipe by tightening the metal strap

worm screw.

WARNING

Failure to properly secure the vent into the elbow with the clamp could lead to property damage, personal injury or loss of life.

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 Vent Pipe - Wall

Mounted Boiler Builds

Refer to Figure 7B and the following Steps:

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.

24 103448-02 - 6/13

Page 25

IV. Venting B. CPVC/PVC Venting (continued)

CHANGE OF DIRECTION

(VERTICAL OR HORIZONTAL)

LONG RUN OF PIPE

L 4

OFFSET

Table 7: Expansion Loop Lengths

Nominal

Pipe Dia.

(In.)

Length of

Straight Run

(Ft.)

20 53 30 65 40 75

Loop Length

“L” (In.)

KEY

RESTRAINT (RESTRICTS MOVEMENT)

HANGER (ALLOWS MOVEMENT)

LOOP

(HORIZONTAL ONLY)

(TOP VIEW)

LOOP LENGTH

(L)

L 4

2 L

50 84 60 92

20 60 30 74

40 85 50 95 60 104

Figure 5: Expansion Loop and Offset

MIN

L 5

MIN

WARNING

Apply supplied silicon dielectric grease from attached pouch to gasket inside vent section of two-pipe vent connector. Failure to apply the grease could result in gasket rupture during vent pipe installation and gasket deterioration due to condensate exposure.

Check if ue exit gasket inside heat exchanger has factory applied silicon grease. If the gasket lubricant

is missing, apply supplied silicon dielectric grease prior to two-pipe vent connector insertion into heat

exchanger ue exit.

Figure 6: Field Installation of CPVC/PVC Two-Pipe Vent System Connector - Floor Mounted Boiler Builds

103448-02 - 6/13 25

Page 26

IV. Venting B. CPVC/PVC Venting (continued)

Table 8: Vent/Combustion Air Pipe Length – Two-Pipe Direct Vent System Options

• CPVC/PVC

• Polypropylene (PP) or Polypropylene (PP)/PVC

• Stainless Steel/PVC or Galvanized Steel)

3” (80 mm)

Boiler Model

ALP080B 30 In. 135 Ft. 30 In. 135 Ft.

ALP105B 30 In. 135 Ft. 30 In. 135 Ft.

ALP150B 30 In. 135 Ft. 30 In. 135 Ft.

ALP210B 30 In. 135 Ft. 30 In. 135 Ft.

ALP285B 30 In. 100 Ft. 30 In. 100 Ft.

ALP399 30 In. 100 Ft. 30 In. 100 Ft.

Combustion Air Pipe

(Equivalent Length)

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

4” (100 mm)

Combustion Air Pipe

(Equivalent Length)

3” (80 mm) Vent Pipe

(Equivalent Length)

4” (100 mm) Vent Pipe

(Equivalent Length)

Vent/Combustion Air Equivalent Length Calculation Work Sheet CPVC/PVC Two-Pipe

Combustion Air Vent

90° Elbow(s) PVC (Installer Supplied) 90° Elbow(s) CPVC (Supplied with Boiler)

Nominal

Diameter, In.

3 10 3 1 10 10

4 13 4 1 13 13

Nominal

Diameter, In.

3 3.0 3 10

4 4.5 4 13

Nominal

Diameter, In.

3 1 3 3.0

4 1 4 4.5

* Total Equivalent Length, Ft. (A+B+C) = 30” (2.5 Ft.) Straight Pipe, CPVC (Supplied with Boiler)

* Note: Total Equivalent Length Calculated Value Cannot Exceed Max. Equivalent Length Values shown in Table 8.

Vent and Combustion Air Terminals Do Not Count Towards Total Equivalent Length.

Quantity

(Pc)

45° Elbow(s) PVC (Installer Supplied) 90° Elbow(s) PVC (Installer Supplied)

Quantity

(Pc)

Straight Pipe, PVC (Installer Supplied) 45° Elbow(s) PVC (Installer Supplied)

Quantity

(Length, Ft.)

Equivalent

Length, Ft/Pc

Equivalent

Length, Ft/Pc

Equivalent

Length, Ft/Ft

Subtotal,

Equivalent

Ft. (A)

Subtotal,

Equivalent

Ft. (B)

Subtotal,

Equivalent

Ft. (C)

Nominal

Diameter, In.

Nominal

Diameter, In.

Nominal

Diameter, In.

Nominal

Diameter, In.

3 2.5 1 2.5

4 2.5 1 2.5

Nominal

Diameter, In.

3 1

4 1

* Total Equivalent Length, Ft. (A+B+C+D+E) =

Quantity

(Pc)

Quantity

(Pc)

Quantity

(Length, Ft.)

Quantity

(Length, Ft.)

Straight Pipe, PVC (Installer Supplied)

Quantity

(Length, Ft.)

Equivalent Length,

Ft/Pc

Equivalent Length,

Ft/Pc

Equivalent Length,

Ft/Ft

Equivalent Length,

Ft/Ft

Equivalent Length,

Ft/Ft

Subtotal,

Equivalent Ft.

(D)

Subtotal,

Equivalent Ft.

(A)

Subtotal,

Equivalent Ft.

(B)

Subtotal,

Equivalent Ft.

(E)

Subtotal,

Equivalent

Ft. (C)

26 103448-02 - 6/13

Page 27

IV. Venting B. CPVC/PVC Venting (continued)

Figure 7A: Near-Boiler Vent/Combustion Air Piping - Floor Mounted Boiler Builds

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

c. Apply supplied dielectric grease (grease pouch

attached to 90° vent elbow outlet inside air box) to gasket inside vent elbow. The grease will prevent gasket rupture when inserting vent pipe and gasket deterioration due to condensate exposure.

6. Horizontal Vent Termination

a. Standard Two-Pipe Termination

See Figures 8 through 11.

i. Vent Piping

Running PVC vent pipe inside Enclosures and

thru Walls:

• PVC vent pipe must be installed in such

way as to permit adequate air circulation around the outside of the pipe to prevent internal wall temperature rising above

ANSI Z21.13 standard specied limit.

• Do not enclose PVC venting – use higher

temperature rated CPVC pipe in enclosed spaces, or, to penetrate combustible or non-combustible walls.

• PVC vent pipe may not be used to penetrate

combustible or non-combustible walls unless all following three conditions are met simultaneously (see Figure 8 “ Wall Penetration Clearances for PVC Vent Pipe”):

103448-02 - 6/13 27

Figure 7B: Field Installation of CPVC Vent Pipe -

Wall Mounted Boiler Builds

- The wall penetration is at least 66 inches from the boiler as measured along the vent

- The wall is 12” thick or less

- An air space of at least of that shown in Figure 8 is maintained around outside of the vent pipe to provide air circulation

• If above three conditions cannot be

met simultaneously when penetrating a combustible wall, use a single wall thimble [US Boiler part numbers 102180-01 (3”) and 102181-01 (4”)].

• Thimble use is optional for non-combustible

wall.

• Insert thimble into cut opening from outside. Secure thimble outside ange to wall with

nails or screws and seal ID and OD with sealant material.

Page 28

IV. Venting B. CPVC/PVC Venting (continued)

Figure 8: Wall Penetration Clearances for PVC Vent Pipe

• When thimble is not used for non-

combustible wall, size and cut wall opening such that a minimal clearance is obtained and to allow easy insertion of vent pipe.

• Apply sealant between vent pipe and

thimble or wall opening to provide weathertight seal. Sealant should not restrain the expansion of the vent pipe.

• Install Rodent Screen and Vent Terminal

(supplied with boiler). See Figure 10 for

appropriate conguration details.

WARNING

All CPVC pipe supplied with boiler vent carton must be used as part of vent system prior to connecting supplied PVC vent terminal.

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

b. Optional Two-Pipe Snorkel Termination

See Figures 10 and 11.

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.

NOTICE

Exterior run to be included in equivalent vent/

combustion air lengths.

i. Vent Piping

• 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

11.

• 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 10 for

appropriate conguration.

• Brace exterior piping if required.

ii. Combustion Air Piping

• After penetrating wall, install a Schedule 40

PVC 90° elbow so that elbow leg is in the up direction.

• Install maximum vertical run of seven (7) feet

of Schedule 40 PVC vent pipe. See Figure

11.

ii. Combustion Air Piping

• Do not exceed maximum combustion air

pipe length. Refer to Table 8.

• Size combustion air pipe wall penetration

opening to allow easy insertion of the pipe.

• Install Rodent Screen and Combustion Air

Terminal (supplied with boiler). See Figure

10 for appropriate conguration details.

• Apply sealant between combustion air pipe

and wall opening to provide weather-tight seal.

CAUTION

To avoid cross-contamination, extend the distance between adjacent vent terminations.

28 103448-02 - 6/13

Figure 9A : Direct Vent - Sidewall Terminations

Page 29

IV. Venting B. CPVC/PVC Venting (continued)

7. Vertical Vent Termination

a. Standard Two-Pipe Termination Refer to Figures 8, 10, 12 and 13.

i. Vent Piping

• 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 12 and

13.

- 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

Figure 9B : Direct Vent - Sidewall Terminations

(Optional)

Figure 10: Rodent Screen Installation

• At top of air 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

10 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 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.

Figure 11: Direct Vent - Optional Sidewall

Snorkel Terminations

103448-02 - 6/13 29

Page 30

IV. Venting B. CPVC/PVC Venting (continued)

• Install Rodent Screen and Vent Terminal

(supplied with boiler), see Figure 10 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 flashing 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

Figure 12: Direct Vent - Vertical Terminations

Sealant between combustion air pipe and storm collar to provide weathertight seal.

• Install Rodent Screen and Combustion Air

Terminal (supplied with boiler), see Figure

10 for appropriate conguration.

• Brace exterior piping if required.

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. Allow additional vertical (‘X’) distance for expected snow accumulation.

30 103448-02 - 6/13

Figure 13: Direct Vent - Vertical Terminations

with Sloped Roof

Page 31

IV. Venting C. Polypropylene Venting (continued)

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.

C. Polypropylene Venting

Alpine boilers have been approved for use with

polypropylene vent system.

It is an installing contractor responsibility to procure

listed below polypropylene vent system pipe and related

components.

Polypropylene vent system manufactures are listed below:

Approved Polypropylene Vent System Manufacturers

Make Model

M&G/DuraVent

Centrotherm Eco

Systems

NOTE: Do not mix vent components from approved manufacturers.

PolyPro Single Wall Rigid Vent PolyPro Flex Flexible Vent InnoFlue SW Rigid Vent Flex Flexible Vent

M&G/DuraVent PolyPro Single Wall Rigid Vent and

PolyPro Flex Flexible Vent comply with the requirements of ULC-S636-08 ‘Standard for Type BH Gas Venting Systems’.

Centrotherm Eco Systems InnoFlue SW Rigid Vent

and Flex Flexible Vent comply with the requirements of UL 1738 ‘Standard for Safety for Venting Systems’ and ULC-S636-08 ‘Standard for Type BH Gas Venting Systems’.

For polypropylene vent system installation details refer

to an approved manufacturer either Rigid Single Wall Polypropylene Vent Installation Instructions, or Flexible Polypropylene Vent Installation Instructions provided with

a manufacturer specic kits. See Tables 9 and 10 below.

Refer to Table 8 ‘Vent/Combustion Air Pipe Length –

Two-Pipe Direct Vent System Options’ for minimum and maximum listed equivalent length values.

All terminations must comply with listed options for two-

pipe venting system. See Figures 8 thru 12 for details.

When using exible polypropylene vent pipe (liner):

• Flexible pipe must be treated carefully and stored

at temperatures higher than 41°F (5°C).

• Do not bend or attempt to install exible pipe if

it has been stored at lower ambient temperature without allowing the pipe to warm up to a higher

temperature rst.

Table 9: Approved Polypropylene Pipe, Fittings and Terminations - M&G/DuraVent

M&G / DuraVent Part Numbers/Sizes Boiler Model

ALP080B

ALP105B

ALP150B

ALP210B

ALP285B

ALP399

Boiler Adapter,

PVC to PP

3PPS-AD

and 4PPS-AD

4PPS-AD 100 mm 100 mm 4PPS-LB 4PPS-TB 4PPS-FK

Boiler

Adapter

Connector

PPS-PAC

Rigid Pipe Flex Pipe

80 mm 80 mm 3PPS-LB 3PPS-TB

80 mm

and 100 mm

80 mm

and 100 mm

Pipe Joint

Locking Band

3PPS-LB

and 4PPS-LB

Side Wall

Termination Tee

3PPS-TB 4PPS-TB

Table 10: Approved Polypropylene Pipe, Fittings and Terminations - Centrotherm Eco

Centrotherm Eco Part Numbers/Sizes Boiler Model

ALP080B ALP105B

ALP150B

ALP210B

ALP285B

ALP399

Boiler Adapter,

PVC to PP

ISAA0303

ISSAL0303

ISAA0303

ISSAL0303

ISAA0404

ISSAL0404

ISAA0404

ISSAL0404

Boiler

Adapter

Connector

N/A

Rigid Pipe Flex Pipe

80 mm 80 mm IANS03 ISTT03

80 mm

and 110 mm

110 mm 110 mm IANS04 ISTT04

80 mm

and 110 mm

Pipe Joint

Locking Band

IANS03

and

IANS04

Side Wall

Termination Tee

ISTT03

ISTT04

and

Chimney Kit for

Venting Only

3PPS-FK

Chimney Kit for

Venting Only

IFCK0325

and

IFCK0335

IFCK0425

and IFCK0435

103448-02 - 6/13 31

Page 32

IV. Venting C. Polypropylene Venting (continued)

CAUTION

Bending or attempting to install exible pipe if it

has been stored at ambient temperature below 41°F (5°C) will cause material to become brittle and lead to cracks.

• When exible polypropylene pipe (liner) is used

for combustion product venting, it must not be

installed at an angle greater than 45 degrees

from vertical plane. This will insure proper

condensate ow back towards the boiler.

CAUTION

Do not install exible polypropylene pipe at an

angle greater than 45 degrees from vertical plane when used for combustion product venting. Failure to do so will result in improper condensate drainage towards the boiler and possible

subsequent vent pipe blockage.

• When exible polypropylene pipe (liner) is used

for combustion air supply to a boiler, the pipe (liner) can be installed in vertical or horizontal position.

• Follow flexible polypropylene pipe (liner) manufacturer specic installation instructions

regarding application/listing, permits, minimum clearances to combustibles; installation details (proper joint assembly, pipe support and routing,

gasket and tting installation, optional tooling

availability/usage, routing thru masonry chimney for combustion product venting or, combination of combustion product venting and combustion air supply).

• When there is a conflict between flexible polypropylene pipe (liner) manufacturer installation instructions and Alpine boiler Installation, Operating and Service Instructions, the more restrictive instructions shall govern.

Alpine Boiler Two-Pipe Vent System Connector Field

Modication Procedure To Accept Polypropylene Vent

Piping – Floor Mounted Boiler Builds:

Alpine oor mounted boilers are factory supplied with a

model-specic boiler two-pipe CPVC/PVC vent system connector shipped within a model-specic boiler CPVC

gasketed vent kit carton.

Locate and remove a model-specic boiler two-pipe CPVC/

PVC vent system connector.

When using M&G/DuraVent polypropylene pipe for

combustion product venting modify the two-pipe vent

system connector upper vent connection port (has a ue

temperature sensor port welded on the side) to accept a PVC to PP boiler adapter, as follows (See Figure 14 ):

Figure 14: Vent System Field Modication to Install PVC to PP Adapter (M&G/DuraVent Shown)

32 103448-02 - 6/13

Page 33

IV. Venting C. Polypropylene Venting (continued)

1) Remove external worm band clamp from upper vent connection port of the two-pipe vent system connector.

2) Using needle nose pliers grasp one of three spot welded band clamp straps, close to a spot weld, and reverse bend towards vent system connector body.

3) Repeat the same with two remaining clamp straps.

4) Apply provided dielectric grease (grease pouch taped to the vent system connector) all around to the vent connection inner red silicon gasket.

5) Lubricate PVC to PP boiler adapter (3PPS-AD or 4PPS-AD as applicable) outer seal with water, than, push and twist the adapter into the vent connection port until bottomed out.

Figure 15: Field Installation Procedure to Accept

Polypropylene Vent Piping - Wall Mounted Boiler

6) Install boiler adapter connector PPS-PAC to secure PVC to PP boiler adapter to the vent connection port of boiler two-pipe system connector.

7) Attach modied two-pipe system adapter to boiler.

See Figure 5 for details.

8) Lubricate PVC to PP boiler adapter inner seal with water, than, push and twist a rigid PP pipe male end into PVC to PP boiler adapter female end until bottomed out.

9) When also using M&G/DuraVent polypropylene pipe for combustion air supply to boiler repeat the step 1 to modify the lower combustion air supply port of the vent system connector to accept PVC to PP boiler adapter.

10) Do not modify the lower combustion air supply port of the two-pipe vent system connector when using PVC pipe for combustion air supply to boiler.

When using Centrotherm Eco polypropylene pipe for

combustion product venting and/or air supply PVC to PP boiler adapter (ISAA0303 or ISAA0404 as applicable) is installed into the two-pipe vent system connector vent or combustion air supply port as follows:

Table 11: Polypropylene Vent System and Combustion Air System Components Equivalent Length vs.

Component Nominal Diameter

Vent or Combustion Air System

Component Description

Component Nominal Diameter, mm 80 mm 100 mm (110 mm)

87° Elbow 10 13 45° Elbow 3.0 4.5

Rigid Single Wall 80 mm Polypropylene Pipe x 1 ft. 1 Rigid Single Wall 80 mm Polypropylene Pipe x L ft. long Multiply L by 1 Rigid Single Wall 100 mm (110 mm)

Polypropylene Pipe x 1 ft. Rigid Single Wall 100 mm (110 mm)

Polypropylene Pipe x L ft. long Flexible 80 mm Polypropylene Pipe x 1 ft. 1.2 Flexible 80 mm Polypropylene Pipe x L ft. long Multiply L by 1.2 Flexible 100 mm (110) Polypropylene Pipe x 1 ft. 1.2 Flexible 100 mm (110) Polypropylene Pipe x L ft. long Multiply L by 1.2

103448-02 - 6/13 33

Equivalent Length (Ft.) for Vent or Combustion Air System

Component vs. Component Nominal Diameter (mm)

Multiply L by 1

Page 34

IV. Venting C. Polypropylene Venting (continued)

11) Apply provided dielectric grease (grease pouch taped to the vent system connector) all around to the vent or air connection inner red silicon gasket.

12) Push and twist PVC to PP boiler adapter (ISAA0303 or ISAA0404 as applicable) into two-pipe vent system connector vent connection or air supply port until bottomed out.

13) Tighten the worm band clamp screw to secure PVC to PP boiler adapter.

14) Do not install PVC to PP boiler adapter at the lower combustion air supply port of the two-pipe vent system connector when using PVC pipe for combustion air supply to boiler.

Alpine Boiler Two-Pipe Vent System Field Installation

Procedure To Accept Polypropylene Vent Piping – Wall

Mounted Boiler Builds:

Alpine wall mounted boiler builds have a factory installed

vent connector 90° elbow inside air box and air box top located combustion air collar, See Part B ‘CPVC/PVC

To accept polypropylene piping for venting and/or

combustion air (see Figure 15 “Field Installation Procedure to accept Polypropylene Vent Piping – Wall Mounted Boiler”

15) Install supplied 30” long CPVC pipe into a factory installed vent connector 90° elbow and secure with the elbow band clamp.

16) When using polypropylene pipe for combustion air intake, install a 4” stub of an appropriate diameter PVC air intake pipe (contractor supplied) onto air box top located combustion air collar. Seal the stub

to air box top with silicon all around.

17) Attach and cement an appropriate diameter CPVC coupling (contractor supplied) to previously installed 30” long CPVC pipe exposed end.

18) If using polypropylene pipe for combustion air intake, attach and cement an appropriate diameter PVC coupling (contractor supplied) to exposed end of PVC air intake stub.

Venting’, section ‘Field Installation of CPVC Vent Pipe – Wall Mounted Boiler Builds’ and Figure 6B for details.

Vent/Combustion Air Equivalent Length Calculation Work Sheet for Rigid Polypropylene (PP) Vent

and Air Intake Two-pipe System

Combustion Air - Polypropylene (PP) Vent - Polypropylene (PP)

87° Elbow(s) PP (Installer Supplied) 87° Elbow(s) PP (Installer Supplied)

Nominal

Diameter, mm

80 10 80 1 10

100

(110)

Nominal

Diameter, In.

80 3.0 80 3.0

100

(110)

Nominal

Diameter, In.

80 1 80 1

100

(110)

* Total Equivalent Length, Ft. (A+B+C) =

Notes:

Maximum listed exible polypropylene liner length is 48 feet. Pressure drop for exible polypropylene pipe (liner) is 20% higher than pressure drop for rigid polypropylene pipe. When calculating Total Equivalent Length for a particular venting application where exible polypropylene pipe (liner) is to be used in combination with straight

rigid polypropylene pipe, multiply projected measured length of exible polypropylene pipe (liner) by 1.2 to arrive at corresponding equivalent length of straight rigid polypropylene pipe.

Example:

Projected measured length of exible polypropylene pipe (liner) is 35 feet. Equivalent length of straight rigid polypropylene pipe to be used for Total Equivalent Length calculation is 35 * 1.2 = 42 feet

Quantity

(Pc)

45° Elbow(s) PP (Installer Supplied) 45° Elbow(s) PP (Installer Supplied)

Quantity

(Pc)

Straight Pipe, PP (Installer Supplied) Straight Pipe, PP (Installer Supplied)

Quantity

(Length, Ft.)

Equivalent

Length, Ft/Pc

Equivalent

Length, Ft/Pc

4.5

Equivalent

Length, Ft/Ft

Subtotal,

Equivalent

Ft. (A)

Subtotal,

Equivalent

Ft. (B)

Subtotal,

Equivalent

Ft. (C)

Nominal

Diameter, mm

100

(110)

Nominal

Diameter, In.

100

(110)

Nominal

Diameter, In.

100

(110)

* Total Equivalent Length, Ft. (A+B+C) + 2.5** =

** Add 2.5 ft (30”) Straight Pipe, CPVC (Supplied with Boiler) if used)

Quantity

(Pc)

1 13

Quantity

(Pc)

Quantity

(Length, Ft.)

Equivalent Length,

Ft/Pc

Equivalent Length,

Ft/Pc

4.5

Equivalent Length,

Ft/Ft

Subtotal,

Equivalent Ft.

(A)

Subtotal,

Equivalent Ft.

(A)

Subtotal,

Equivalent Ft.

(B)

34 103448-02 - 6/13

Page 35

IV. Venting C. Polypropylene Venting (continued)

19) Lubricate PVC to PP adapter outer seal with water (or approved water based lubricant), than, insert and push lubricated adapter end into CPVC coupling open end until bottomed out.

20) If using polypropylene pipe for combustion air intake, repeat the above step installing the adapter into PVC air intake.

21) Install the adapter connector (applicable to M&G/ DuraVent vent system only) to secure PVC to PP adapter to a coupling and a polypropylene rigid pipe, either venting and/or air intake.

Table 11 provides polypropylene venting or combustion

air supply system component equivalent length values to calculate the equivalent vent length.

Optional Two-pipe Vertical Venting Installation – Running Flexible Polypropylene Vent (Liner) Thru Unused Chimney Chase (see Figure 16).

Alpine boilers are approved for vertical venting by installing Flexible Vent in an UNUSED masonry chimney/chase and supplying combustion air thru a separate wall or roof air intake terminal.

Figure 16: Flexible Vent in Masonry Chimney

with Separate Air Intake

Venting of Other Appliances (or Fireplace)

into Chase or Adjacent Flues Prohibited!

103448-02 - 6/13 35

Page 36

IV. Venting C. Polypropylene Venting (continued)

WARNING

Follow installation instructions included by the original polypropylene venting component manufacturers, M&G/DuraVent or Centrotherm, whichever applicable.

Flexible Polypropylene Vent must be installed in an UNUSED chimney. A chimney, either single or

multiple ue type, is considered UNUSED when none of the ues is being used for any appliance

venting.

Where one of the multiple ues is being used for an appliance venting, the exible vent installation is not permitted thru any of adjacent ues.

Observe all precautions outlined in either M&G/DuraVent or Centrotherm instructions in addition to those outlined in these instructions.

Examine all components for possible shipping damage prior to installation. Proper joint assembly is essential for safe installation. The venting system must be free to expand and contract and supported in accordance with installation

instructions included by the original polypropylene venting component manufacturers, M&G/DuraVent or Centrotherm, whichever applicable.

Do not mix vent components or joining methods for different vent systems.

Where a conict arises between M&G/DuraVent or Centrotherm instructions and these instructions, the

more restrictive instructions shall govern.

Do not apply thermal insulation to vent pipe and ttings.

Do not obtain combustion air from within the building.

Table 12: Summary of PP Flex Two-Pipe Direct Vent System Option

Approved Two-Pipe Direct Vent System Option

Classication Used In These Instructions

Vent Exhaust Penetration Thru Structure Chimney Cap Air Intake Penetration Thru Structure Side Wall or Roof terminal Min. Round Chase Inside Diameter, inch 5 6 Min. Rectangular Chase Inside Dimensions, inch 5 x 5 6 x 6 Nominal Poly Pro Flex (M&G/DuraVent) Liner Size, mm 80 100 Nominal Flex (Centrotherm Eco) Liner Size, mm 80 110 Maximum Total Equivalent Vent Length (Including Flexible Vent Liner in Chase), ft

ALP080B ALP105B ALP150B ALP210B ALP285B ALP399

Maximum Actual Length of Flexible Polypropylene Liner, ft 48 48 Maximum Equivalent Length of Flexible Polypropylene Liner, ft 58 58

UNUSED Chimney Chase Installation -

Flexible Vent Pipe and separate Air Intake

M&G/DuraVent Poly Pro Flex

Centrotherm Eco Flex

135 NA

NA 100

36 103448-02 - 6/13

Page 37

IV. Venting D. Stainless Steel Venting (continued)

D. 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.

1. 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 8. 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’, Paragraph A.5. (Refer to Figure 4)

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.

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 17).

Figure 17: 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.

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 13A and 13B for approved AL29C

Vent Systems.

c. Do not exceed maximum Vent/Combustion air

length. Refer to Table 8.

d. Follow all manufacturer instructions and warnings

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

Table 13A: U.S. Boiler Company Vent System

Components (Stainless Steel)

Part Numbers

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

ALP080B -

210B

3" Vent 4" Vent

8116310 8116313

102219-01 102220-01

ALP285B -

399

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")

103448-02 - 6/13 37

Page 38

IV. Venting D. Stainless Steel Venting (continued)

Table 13B: Alternate Vent Systems and Vent Components (Stainless Steel)

Manufacturer

Protech

Systems

Inc..

Z-Flex

Flex-L Intl. Star-34

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

and vent supports.

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

• Install a rodent screen (not supplied) in the

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.

Horizontal Vent Termination

a. Standard Two-Pipe Termination Refer to Figure 9A.

i. Vent Termination

• Use U.S. Boiler Company 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.

• 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.

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 9A.

b. Optional Two-Pipe Snorkel Termination Refer to Figure 11.

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

ii. Combustion Air Termination

Vertical Vent Termination

a. Standard Two-Pipe Termination Refer to Figures 12 and 13.

i. Vent Termination

inlet terminal. Use a screen having 1/2”

(2 x 2) or larger mesh.

• 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 11.

• 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.

• 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 11.

• At top of vent pipe length install another

90° elbow os that the elbow leg is opposite the building’s exterior surface.

• Install Rodent Screen (not supplied) and

horizontal vent terminal.

• Brace exterior piping if required.

• Use the terminal supplied by the vent

system manufacturer shown in Table 13B.

Vertical

Termination

38 103448-02 - 6/13

Page 39

IV. Venting D. Stainless Steel Venting (continued)

Follow manufacturer’s instructions to attach terminal to vent system.

ii. Combustion Air Termination

• Install vertical combustion air terminal.

Vertical combustion air terminal consists of an 180° bend (comprised of two (2) 90° elbows) as shown in Figure 12.

• Install rodent screen (not supplied) in the

combustion air terminal. Use a screen having 1/2” (2 x 2) or larger mesh.

E. Concentric Polypropylene Venting

1. Vent Length Restrictions

a. Vent length restrictions are based on equivalent

length of vent pipe i.e. total length of straight pipe

plus equivalent length of ttings. See Table 14 for specied vent length details. Do not exceed

maximum vent length. Table 15 lists available concentric vent components and includes equivalent

vent length for ttings.

b. The vent termination location is restricted as per

‘General Guidelines’, Paragraph A, 5 (refer to Figure 4).

Table 15: Concentric Vent Components

Part Number Component Description Size

101493-01 90° Elbow – Long Radius 80/125 mm 5.5 101491-01 45° Elbow - Long Radius 80/125 mm 3.0 101163-01 Cut -To-Length Extension, 500 mm (19-1/2”) 80/125 mm 1.63 **Can be cut 101162-01 Cut -To-Length Extension, 1000 mm (39”) 80/125 mm 3.25 **Can be cut 101485-01 Fixed Extension, 2000 mm (78”) 80/125 mm 3.25 ***Must not be cut 101808-01 Horizontal (Wall) Terminal 80/125 mm *NA Supplied with boiler 101495-01 Vertical Roof Terminal 80/125 mm *NA See Note 1 101496-01 Flat Roof Flashing 80/125 mm 101497-01 Sloped Roof Flashing 80/125 mm See Note 2 101492-01 Support Elbow with Chimney Chase Bracket 80/125 mm 8.5 See Note 3 101498-01 Hanger Wall Bracket 80/125 mm 101909-01 Locking Clamp 80/125 mm 101548-01 90° Elbow – Long Radius 100/150 mm 8.0 101549-01 45° Elbow - Long Radius 100/150 mm 3.0 101550-01 1 Cut -To-Length Extension, 500 mm (19-1/2”) 100/150 mm 1.63 ** Can be cut 101551-01 Cut -To-Length Extension, 1000 mm (39”) 100/150 mm 3.25 ** Can be cut 101553-01 Fixed Extension, 2000 mm (78”) 100/150 mm 6.5 *** Must not be cut 101809-01 Horizontal (Wall) Terminal 100/150 mm * NA Supplied with boiler 101557-01 Vertical (Roof) Terminal 100/150 mm * NA See Note 1 101558-01 Flat Roof Flashing 100/150 mm 101559-01 Sloped Roof Flashing 100/150 mm See Note 2 101560-01 Support Elbow with Chimney Chase Bracket 100/150 mm 10.0 See Note 3 101561-01 Hanger Wall Bracket 100/150 mm 103097-01 Locking Clamp 100/150 mm

Notes: * NA – do not include vent terminal into total vent length calculations. ** These sections have plain male end and beaded female end. See Figure 19 for details. *** These sections have beaded male end and beaded female end. See Figure 20 for details.

1. Vertical terminal can be used with either of the roof ashings listed beneath it.

2. Sloped roof ashing suitable for roof angles between 25° and 45°.

3. Used at base of vertical run inside unused masonry chimney.

103448-02 - 6/13 39

Table 14: Concentric Vent Length

Boiler Model

ALP080B ALP105B ALP150B ALP210B ALP285B

ALP399

* with optional concentric vent components, see Table 15 for

details.

Inner/Outer

Pipe Dia.,

80/125 mm 21-7/8 in

100/150

Field Installation of Boiler Concentric Vent

Vent Length (Equiv. Ft.)

Minimum * Maximum

32 in 6-1/2 in

Opening

Diameter

5-1/2 in

Collar

a. Locate and remove six mounting screws from the

Miscellaneous Parts Carton.

b. Position the Collar onto jacket combination rear/

bottom panel and insert collar inner stainless steel vent pipe into the heat exchanger vent outlet.

c. Align collar plate clearance holes with rear/bottom

panel engagement holes; then secure the collar to rear/bottom panel with six mounting screws. See Figure 18.

Component Equivalent

Vent Length, Ft

Comments

Wall

Page 40

IV. Venting E. Concentric Polypropylene Venting (continued)

d. Flue temperature sensor, factory attached to the

boiler wiring harness, is secured to the left boiler jacket panel with tape.

e. Remove the tape and push the sensor rubber plug

into Concentric Vent Collar sensor port until the plug is securely engaged. See Figure 18.

The installation of the Concentric Vent Collar is now

completed.

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. Do not exceed maximum Concentric vent length.

Refer to Table 14.

c. If additional concentric vent piping is needed:

i. Concentric Vent Cut-To-Length Extension

pipes, identied in Table 15 CAN BE CUT to required length when used as an extension.

These pipes have plain male end and beaded

female end. Always cut the pipe from plain male end. See Figure 19 ‘Cut-To-Length

Extension (Cuttable)”.

ii. The remaining Concentric Vent Fixed

Extensions shown in Table 15 CANNOT BE CUT. These pipes have beaded male and beaded female ends. See Figure 20 “Fixed Extension (Non-Cuttable)’.

d. To cut the Concentric Vent Straight pipe to required

length refer to Figure 21 “Cutting Straight Pipe” and the following procedure:

i. Determine the required length of the outer

pipe. When doing this allow an additional 1” of length for insertion into the female end of the adjoining pipe. Mark the cut line on the outer pipe.

ii. Remove the plastic inner pipe by pulling it out

from the female end.

iii. Cut the OUTER PIPE ONLY at the point

marked in Step (a) using aviation shears, a hacksaw, or an abrasive wheel cutter. Be careful to cut the pipe square. De-burr the cut

end with a le or emery cloth.

iv. Make an insertion mark 1” from the male end

of the outer pipe.

v. Cut the plastic inner pipe so that it will protrude

3/8” beyond the male end of the outer pipe when

reinstalled in the outer pipe. Use a ne tooth

hacksaw or a PVC saw to cut the plastic pipe and be careful to cut the pipe square. De-burr

the cut edge of the plastic pipe with a le, razor blade or ne sandpaper.

vi. Reinstall the inner pipe.

e. To join Concentric Vent Pipe refer to Figure 22

“Joining Cuttable Pipe” and Figure 23 “Joining Non-Cuttable Pipe” and follow the procedure below:

i. Start assembly of the vent system at the boiler.

Lubricate the brown gasket in the boiler vent collar with a few drops of water.

ii. Push the male end of the rst tting into the

boiler collar until it bottoms out. The male end of cuttable sections should go 1” into the collar until the insertion mark (made in Step 4

above) is covered. On other ttings, the bead

on the male pipe will be bottom out on the collar (see Figure 22).

40 103448-02 - 6/13

Figure 18: Field Installation of Boiler

Concentric Vent Collar

Page 41

IV. Venting E. Concentric Polypropylene Venting (continued)

Figure 19: Cut-To-Length Extension (Cuttable)

Figure 20: Fixed Extension (Non-Cuttable)

Figure 21: Cutting Straight Pipe

iii. The male end of cuttable ttings must be held

to the collar with three (3) #10 x 1/2” sheet metal screws. Drill a 1/8 hole through both outer pipes to start this screw. Use a drill stop

or other means to ensure that the drill bit does not penetrate more than 3/8” into the

outer pipe. Do not use a sheet metal screw longer than 1/2” (see Figure 23).

Figure 22: Joining Cuttable Pipe

iv. Use locking bands (provided with all ttings)

to secure non-cuttable pipe, as well as ttings,

to the boiler collar (see Figure 23).

v. Use the same method to join all remaining vent

components except for the terminal.

Figure 23: Joining Non-Cuttable Pipe

103448-02 - 6/13 41

Page 42

IV. Venting E. Concentric Polypropylene Venting (continued)

4. Horizontal Vent Termination

a. Standard Concentric Termination Refer to Figure 24.

i. Permitted terminals for horizontal venting:

Horizontal (Wall) Terminal, [80/125 mm

(P/N 101808-01), 100/150 mm (P/N 101809-01] - see Table 15.

ii. Concentric Vent components supplied with

the boiler are packed inside boiler carton and include the following:

• Horizontal (Wall) Terminal,

• Horizontal (Wall) Terminal consists of

Straight section having plain male end with locking band clamp installed; Terminal Assembly with offset vent termination, and Outside Wall Plate, both riveted on the opposite end; overall length is approximately 28-1/8”.

• Separate Inside Wall Plate

• Two Hardware Bags (each bag contains

four screws and four anchors) to attach vent terminal Outside Wall Plate to exterior wall and Inside Wall Plate to interior wall.

iii. For horizontal (sidewall) installation, the

Horizontal (Wall) Terminal will extend past outer wall surface by 4¼” (80/125 mm) or 5½” (100/150 mm). See Figure 24 “Horizontal Concentric Venting”.

iv. Install the Horizontal (Wall) Terminal:

• Cut a 5½” diameter hole through the exterior

wall opening (for 80/125 mm concentric vent) or 6½” (for 100/150 mm) at the planned location of the horizontal terminal.

• Measure dimension “L” from exterior wall outer surface to the end of the last tting.

See Figure 25 ‘Dimension “L”’.

• When factory Horizontal (Wall) Terminal

needs to be shortened, measure dimension “L” plus 1¼” from inside of the attached Outside Wall Plate and mark the Horizontal (Wall) Terminal outer pipe. To achieve a square cut of the outer pipe, place several marks around the outer pipe to establish a cut line. See Figure 26 ‘ Cutting Vent Terminal Pipe’.

• Carefully cut the outer pipe at the marked

line using aviation shears, a hacksaw etc. Ensure the pipe is cut square and cut end is de-burred.

• Mark the end of the Horizontal (Wall)

Terminal inner polypropylene vent pipe to extend 3/8” past the cut end of the outer pipe.

Figure 24: Horizontal Concentric Venting

Figure 25: Dimension “L”

To achieve a square cut of the inner pipe, place several marks around the inner pipe to establish a cut line.

• Cut off the marked end of inner polypropylene vent pipe with a ne tooth blade hacksaw

etc. and de-burr. See Figure 26 “Cutting Vent Terminal Pipe.

This pipe can be removed from the terminal

to ease cutting, if desired.

42 103448-02 - 6/13

Page 43

IV. Venting E. Concentric Polypropylene Venting (continued)

Figure 26: Cutting Vent Terminal Pipe

CAUTION

Exterior wall surface must be reasonably at to

attach the Outside Wall Plate. When exterior wall

surface is not at (covered with vinyl or wood

shingle siding etc.) the siding must be removed,

and a at surface build up ash or above siding

exterior surface to secure/seal the terminal Outside Wall Plate.

• Install the supplied Inside Wall Plate onto the

shortened Horizontal (Wall) Terminal interior end and move the plate to cover interior wall cut opening. Secure the plate with provided fasteners, then, apply the sealant around plate sides to seal it to interior wall (refer to Figure

27).

• Lubricate the brown gasket inside boiler

concentric vent collar or the last section of the vent pipe with small amount of water.

• Ensure that inner pipe of the terminal is evenly

engaged into the gasket all around, then push the termination male end inside boiler concentric vent collar or the last section of the vent pipe, until the mark (see Step v) is no longer visible.

• Re-install locking band clamp onto the joint

to secure the terminal to the collar or the last section of the vent pipe.

Figure 27: Completing Horizontal (Wall Terminal Installation)

103448-02 - 6/13 43

Page 44

IV. Venting E. Concentric Polypropylene Venting (continued)

Vertical Vent Termination

a. Standard Concentric Termination Refer to Figures 28 thru 32.

i. In addition to the vertical terminal, either a

Flat Roof Flashing or Sloped Roof Flashing is required for this installation. Refer to Table 15 ‘Concentric Vent Components’ for details.

• Determine the centerline of the terminal location on the roof. For at roof, cut 5½”

diameter hole (80/125 mm concentric vent size) or 6½” (100/150 mm) for the terminal. For sloped roof, cut a hole in the roof large enough for the terminal to pass through the roof while remaining plumb.

b. Optional Concentric Chimney Chase Installation Refer to Figure 32.

CAUTION

If the boiler is located directly under the hole, cover it while cutting the hole to prevent debris from falling onto boiler.

• Install the roof flashing using standard practice on the roong system of the structure.

• If not already done, assemble the venting

system inside the building. The last section of pipe needs to be on the same center line as the terminal and within 19-1/4” of the top

edge of the roof ashing.

• Measure distance “H” from the top edge of the storm collar to the end of the last tting

as shown in Figure 29.

• Add 1” to distance “H”. Carefully mark this

length on the pipe as shown in Figure 30.

• Cut the outer pipe only at the point marked in Step (e) using aviation shears, a hacksaw, or an abrasive wheel cutter. Be careful to cut the pipe square. De-burr the cut end with a

le or emery cloth.

• Place a mark on the plastic inner pipe 3/8”

beyond the end of the outer pipe (Figure 30).

Use a ne tooth hacksaw to cut the plastic

pipe and be careful to cut the pipe square. De-burr the cut edge of the plastic pipe with

a le or emery cloth.

• Make a mark on the terminal section 1” from

the cut end of the outer pipe as shown in Figure 30.

• Slip the terminal section through the roof

from the outside. Push into the last section of vent pipe until the mark made in Step (h) is not longer visible. Secure the terminal to the last piece of pipe with three #10 x 1/2” sheet metal screws. Drill a 1/8” hole through both outer pipes to start these screws. Use a

drill stop or other means to ensure that the drill bit does not penetrate more than

44 103448-02 - 6/13

F. Removing the Existing Boiler

For installations not involving the replacement of an

existing boiler, proceed to Step F.

When an existing boiler is removed from a common venting

system, the common venting system is likely to be too large for proper venting of the remaining appliances. At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation:

1. Seal any unused openings in the common venting system.

2. Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or

restriction, leakage, corrosion, and other deciencies

which could cause an unsafe condition.

3. Insofar as is practical, close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range-hoods and bathroom exhausts, so they will operate at maxi mum speed. Do not operate

a summer exhaust fan. Close replace dampers.

3/8” into the outer pipe. Do not use a sheet

metal screw longer than 1/2”.

• Secure the terminal section to the inside of

the roof structure using the mounting bracket provided with the terminal (Figure 31).

i. A vertical concentric vent system can be

installed in an UNUSED masonry chimney.

• The Chimney chase Support Elbow with

attached Mounting Bracket is used at the base of the chimney. Refer to Table 15 ‘Concentric Vent Components’ for details. Slip the elbow over the M10 x 35 screw in the support bracket. Determine the desired vertical location of the support elbow in the chimney and mark the location of the pin, positioned on the back of the support bracket, onto the chimney rear wall. Drill a 7/16” diameter x 3-1/2” deep hole in the marked location, then, insert the back bracket pin into the hole. The front of the elbow mounting bracket should be supported either by bottom of the opening into chimney or installer supplied spacer.

• Construct a weather-tight at roof to cover

the top of the old chimney. Install the vertical

terminal through this roof using the at roof ashing.

Page 45

IV. Venting F. Removing the Existing Boiler (continued)

Figure 28: Vertical Concentric Vent Installation

Figure 29: Dimension "H"

Figure 30: Cutting Vertical Terminal

Figure 31: Completing Vertical Terminal Installation

103448-02 - 6/13 45

Page 46

IV. Venting F. Removing the Existing Boiler (continued)

Figure 32: Chimney Chase Installation

4. Place in operation the appliance being inspected. Follow the Lighting (or Operating) Instructions. Adjust thermo stat so appliance will operate continuously.

5. Test for spillage at the draft hood relief opening after

ve (5) minutes of main burner operation. Use the ame of a match or candle, or smoke from a cigarette,

cigar or pipe.

6. After it has been determined that each appliance remain ing connected to the common venting system properly vents when tested as outlined above, return

doors, win dows, exhaust fans, replace dampers and

any other gas burning appliance to their previous conditions of use.

7. Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code, NFPA 54/ANSI Z223.1. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Part II in the National Fuel Gas Code, NFPA 54/ANSI Z223.1.

Au moment du retrait d’une chaudière existante,

les mesures suivantes doivent être prises pour chaque appareil toujours raccordé au système d’evacuation commun et qui fonctionne alors que d’autres appareils toujours raccordés au système d’évacuation ne fonctionnent pas:

1. Sceller toutes les ouvertures non utilisées du système d’évacuation.

2. Inspecter de facon visuelle le système d’évcuation pour déterminer la grosseur et l’inclinaison horizontale qui conviennent et s’assurer que le système est exempt d’obstruction, d’étranglement, de fuite, de corrosion et autres défaillances qui pourraient présenter des risques.

3. Dans la mesure du possible, fermer toutes les portes et les fenêtres du bâtiment et toutes les portes entre l’espace où les appareils toujours raccordés au système d’évacuation sont installés et les autres espaces du bâtiment. Mettre en marche les sécheuses, tous les appareils non raccordés au système d’évacuation commun et tous les ventilateurs d’extraction comme les hottes de cuisinière et les ventilateurs des salles de bain. S’assurer que ces ventilateurs fonctionnent à la vitesse maximale. Ne pas faire fonctionner les ventilateurs d’été. Fermer les registres des cheminées.

4. Mettre l’appareil inspecté en marche. Suivre les instructions d’allumage. Régler le thermostat de facon que l’appareil fonctionne de facon continue.

5. Faire fonctionner le brùleur principal pendant 5 min ensuite, déterminer si le coupe-tirage déborde

à l’ouverture de décharge. Utiliser la amme d’une

allumette ou d’une chandelle ou la fumée d’une cigarette, d’un cigare ou d’une pipe.

6. Une fois qu’il a été déterminé, selon la méthode indiquée ci-dessus, que chaque appareil raccordé au système d’évacuation est mis à l’air libre de facon adéquate. Remettre les portes et les fenêtres, les ventilateurs, les registres de cheminées et les appareils au gaz à leur position originale.

7. Tout mauvais fonctionnement du système d’évacuation commun devrat être corrigé de facon que l’installation soit conforme au National

Fuel Gas Code, ANSI Z223.1 et (ou) aux codes d’installation CAN/CSA-B149.1. Si la grosseur

d’une section du système d’évacuation doit être

modiée, le système devrait être modié pour

respecter les valeurs minimales des tableaux pertinents de l’appendice F du National Fuel Gas

Code, ANSI Z223.1 et (ou) des codes d’installation CAN/CSA-B149.1.

G. Multiple Boiler Installation Venting

1. CPVC/PVC or Polypropylene Venting

a. Multiple Boiler CPVC/PVC or polypropylene

direct venting is shown in Figure 33.

b. Each individual module (boiler) must have own

vent pipe and vent terminal. Refer to Section IV “Venting” of this manual for individual module (boiler) venting guidelines and options.

46 103448-02 - 6/13

Page 47

IV. Venting G. Multiple Boiler Installation Venting (continued)

103448-02 - 6/13 47

Figure 33: Multiple Boiler Direct Vent Termination

Page 48

IV. Venting G. Multiple Boiler Installation Venting (continued)

WARNING

No common manifolded venting (vent piping and vent terminals) is permitted.

c. The individual module (boiler) maximum vent

length - see Section IV, “Venting”, Table 8.

d. For sidewall venting the minimum horizontal

distance between any adjacent individual module (boiler) vent terminations is twelve (12) inches.

Additional horizontal spacing between any adjacent

individual module (boiler) vent terminations as well as extending the distance from building surfaces to vent termination end are 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 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.

e. Individual module (boiler) sidewall vent

terminals must be placed at least twelve (12) inches above the ground plus the expected snow accumulation.

f. Multiple individual module vertical vent pipes

may be piped through a common conduit or chase so that one roof penetration may be made.

The minimum horizontal distance between any

adjacent individual module (boiler) roof vent terminations is one (1) foot.

2. PVC Pipe Air Intake Piping

a. Multiple Boiler PVC air intake piping is shown

in Figure 33.

b. Each individual module (boiler) must have own

combustion air intake pipe and combustion air intake terminal. Refer to Section IV “Venting” of this manual for individual module (boiler) combustion air intake guidelines and options.

c. The individual module (boiler) maximum

combustion air intake pipe length - see Section IV, “Venting”, Table 8.

d. If possible, locate each individual module

(boiler) both combustion air intake termination and vent termination on the same sidewall, to prevent nuisance boiler shutdowns.

However, if same sidewall placement is

problematic, an individual module (boiler) may be installed using vertical venting and sidewall combustion air intake termination (or, vice versa)

3. Concentric Combination Venting/Combustion

Air Intake Piping

a. Concentric Combustion Venting and air intake is

shown in Figure 34.

b. Each individual module (boiler) must have

own concentric vent pipe and vent termination. Follow Section IV “Venting” of this manual for individual module (boiler) concentric venting guidelines.

WARNING

No common manifolded concentric venting is permitted.

c. The individual module (boiler) maximum

concentric vent length - see Section IV, “Venting”, Table 8.

d. For sidewall venting any adjacent individual

module (boiler) concentric vent terminals must be spaced no closer than 12 inches horizontally and three (3) feet vertically from each other to prevent combustion air contamination.

Additional horizontal spacing between any

adjacent individual module (boiler) concentric vent terminations and increased distance from building surfaces to concentric vent termination end are recommended to avoid frost damage to building surfaces where vent terminations are placed.

e. Individual module (boiler) sidewall concentric

vent terminals must be placed at least twelve (12) inches above the ground plus the expected snow accumulation.

f. For vertical through the roof venting any

adjacent individual module (boiler) vertical vent terminals, if level with each other, must be spaced no closer than 12 inches horizontally.

If vertical vent terminals cannot end in one

plane, they must be spaced no closer than three (3) feet horizontally.

g. Chimney chase concentric venting is permitted

for modules, when stackable, providing concentric vertical (roof) vent terminals, if level with each other, are spaced no closer then 12 inches horizontally.

If vertical vent terminals cannot end in one

plane, they must be spaced no closer then three (3) feet horizontally.

48 103448-02 - 6/13

Page 49

IV. Venting G. Multiple Boiler installation Venting (continued)

103448-02 - 6/13 49

Figure 34: Multiple Boiler Concentric Vent Termination

Page 50

IV. Venting G. Multiple Boiler Installation Venting (continued)

h. When individual modules (boilers) are installed

in the same horizontal plane, chimney chase vertical concentric venting is permitted provided:

V. Condensate Disposal

A. Condensate Trap and Drain Line.

1. All condensate, which forms in the boiler or vent system, collects in the sump under heat exchanger and leaves the boiler through factory installed condensate trap.

2. The trap allows condensate to drain from sump

while retaining ue gases in the boiler. The trap has factory installed overow switch, which shuts

down the boiler in the event the drain line becomes obstructed, preventing proper condensate removal. Refer to Section XI “Service and Maintenance” for

condensate trap and condensate overow switch

removal and replacement procedure, if required.

3. Note the following when disposing of the condensate:

a. Condensate is slightly acidic, typical pH around

3.5 - 4.5. Do not use metallic pipe or ttings in

the condensate drain line. Do not route the drain line through areas that could be damaged by leaking condensate.

b. Do not route or terminate the condensate drain

line in areas subject to freezing temperatures.

c. If the point of condensate disposal is above the

trap, a condensate pump is required to move the condensate to the drain. Select a condensate pump approved for use with condensing boilers.

If overow from the pump would result in property damage, select a pump with an overow

switch. Wire this switch in series with installer provided external high limit, to shut off the boiler, and, if desired, in series with installersupplied alarm, to trigger an alarm in the event

of overow.

d. Do not attempt to substitute another trap for one

provided with the boiler.

i. Sufcient inside space available at the base

of the chimney to install multiple chimney chase brackets and support elbows.

ii. Spacing between adjacent vertical vent

terminals is in accordance with Item ‘g’ above.

e. In order for boiler to work properly, the boiler

must be leveled during installation.

4. The condensate trap stub is located at boiler left side, below inlet and outlet water pipe connections. Refer to Figures 1A thru 1C.

5. Condensate trap must be lled up with water,

prior to boiler start-up and before connecting

any condensate line to the boiler, to insure

combustion products cannot escape from operating boiler. To ll the trap, inject water in the

amount of 1 cup (8 uid ounces) through condensate trap stub opening. Do not overll the trap.

6. If any additional condensate drain line is needed, construct the extension from PVC or CPVC Schedule 40 pipe. The factory supplied ¾” x 5-5/8” long PVC coupling, located in the Part Carton, must be used to connect drain line to the condensate trap stub. Do not over tighten coupling compression nuts when connecting drain line and condensate trap stub.

WARNING

Failure to install the condensate trap and condensate drain in accordance with the above

instructions could cause ue gas to enter the

building, resulting in personal injury or death.

CAUTION

Boiler condensate is corrosive. Route condensate drain line in a manner such that any condensate leakage will not cause property damage.

Some jurisdictions may require that

condensate be neutralized prior to disposal.

50 103448-02 - 6/13

Page 51

V. Condensate Disposal (continued)

NOTICE

Use materials approved by the authority having jurisdiction.

B. Condensate Neutralizer Installation

1. Some jurisdictions may require that the condensate be neutralized before being disposed of. Follow local codes pertaining to condensate disposal.

2. A Condensate Neutralizer Kit (P/N 101867-01) is available as optional equipment. Follow local codes and instructions enclosed with the kit for Condensate Neutralizer installation.

3. Limestone chips will get coated by neutral salts (product of chemical reaction between limestone and acidic condensate) and lose neutralizing effectiveness over time. Therefore, periodic condensate neutralizer maintenance and limestone chip replacement 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 service and chip replacement.

103448-02 - 6/13 51

Figure 35: Condensate Trap and Drain Line

Page 52

VI. Water Piping and Trim

WARNING

Failure to properly pipe boiler may result in improper operation and damage to boiler or structure.

Install boiler so that the gas ignition system components are protected from water (dripping, spraying, rain, etc.) during boiler operation and service (circulator replacement, etc.).

Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components, and can lead to boiler failure. U.S. Boiler Company’s Standard Warranty does not cover problems caused by

oxygen contamination of boiler water or scale (lime) build-up caused by frequent addition of water.

Do not ll boiler with softened water to prevent chloride contamination.

A. Installation of Factory Supplied Piping and Trim

Components

Alpine (ALP) boilers have factory supplied Miscellaneous

Part Carton (P/N 102942-01 – ALP080B thru ALP210B; 102942-02 or 103676-01 – ALP285B; 102942-03 – ALP399), which includes supply piping components, gas piping components, Temperature & Pressure Gauge,

Pressure Relief Valve and Drain Valve. See Figure 30 “ Factory Supplied Piping and Trim Installation”. Install these components prior to connecting boiler to

system piping as follows:

1. Relief Valve Piping, ALP080B thru ALP210B Boiler Models

a. Locate and remove ¾” NPT x close black nipple,

¾” NPT black tee, ¾” MPT x ¾” FPT Pressure Relief Valve, ¾” NPT Drain Valve.

b. Install close nipple into tee branch, then, screw

the assembly into boiler left side front ¾” tapping making sure tee run outlets are in vertical plane and parallel to boiler side.

c. Mount ¾” MPT x ¾” FPT Pressure Relief Valve

into the tee top outlet.

d. Install Drain Valve into the tee bottom outlet.

Figure 36: Factory Supplied Piping and Trim Installation

52 103448-02 - 6/13

Page 53

VI. Water Piping and Trim A. Factory Supplied Piping and Trim (continued)

2. Relief Valve Piping, ALP285B and ALP399 Boiler Models

a. Locate and remove (1) ¾” NPT x close black nipple,

(1) ¾” NPT x 12” black nipple, ¾” NPT black tee, ¾” FPT x ¾” FPT Pressure Relief Valve, ¾” NPT Drain Valve.

b. Install close nipple into tee branch, then, screw

the assembly into boiler left side front ¾” tapping making sure tee run outlets are in vertical plane and parallel to boiler side.

c. Install the ¾” NPT x 12” black nipple into tee run

top outlet.

d. Mount ¾” FPT x ¾” FPT Pressure Relief Valve

onto the 12” nipple.

e. Install Drain Valve into the tee bottom outlet.

3. Temperature /Pressure Gauge Piping, ALP080B thru ALP210B Boiler Models

a. Locate and remove 1” NPT x 4” long black nipple,

1” x 1” x 1” NPT black tee, 1” x ¼” NPT black reducing bushing and Temperature & Pressure Gauge.

b. Mount the nipple into 1” boiler supply tapping (see

Figures 1A and 1B), then, install the tee onto the nipple, making sure 1” branch outlet is in horizontal plane and facing the boiler front.

c. Install 1” x ¼” NPT black reducing bushing into

the tee branch, then, put in Temperature & Pressure Gauge.

4. Temperature /Pressure Gauge Piping, ALP285B Boiler Model

a. Locate and remove 1¼” NPT x 2” long black

nipple, 1¼” x 1¼” x ¾” NPT black tee, ¾” x ¼” NPT black reducing bushing and Temperature & Pressure Gauge.

b. Mount the nipple into 1¼” boiler supply tapping

(see Figures 1B and 1C), then, install the tee onto the nipple, making sure ¾” branch outlet is in horizontal plane and facing the boiler front.

c. Install ¾” x ¼” NPT black reducing bushing into

the tee branch, then, put in Temperature & Pressure Gauge.

5. Temperature /Pressure Gauge Piping, ALP399 Boiler Model

a. Locate and remove 1½” NPT x 2” long black

nipple, 1½” x 1½” x ¾” NPT black tee, ¾” x ¼” NPT black reducing bushing and Temperature & Pressure Gauge.

b. Mount the nipple into 1½” boiler supply tapping

(see Figures 1B and 1D), then, install the tee onto the nipple, making sure ¾” branch outlet is in horizontal plane and facing the boiler front.

c. Install ¾” x ¼” NPT black reducing bushing into

the tee branch, then, put in Temperature & Pressure Gauge.

B. Piping System To Be Employed.

Alpine (ALP) boilers are designed to operate in a closed

loop pressurized system. Minimum pressure in the boiler must be 12 PSI. Proper operation of the Alpine

(ALP) boiler requires that the water ow through the

boiler remain within the limits shown in Table 16, any

time the boiler is ring.

NOTICE

Failure to maintain the ow through boiler within specied limits could result in erratic operation or

premature boiler failure.

1. Near boiler piping must isolate ALP boiler from system piping via closely spaced tees to insure

specied ow range through boiler any time the boiler is ring:

a. The ow rate through the isolated near-boiler

loop is maintained by factory recommended and installer supplied boiler circulator.

b. The ow rate through the isolated near-boiler

loop is completely independent of the ow rate through the heating system loop(s).

c. The ow rate through the heating system loop(s)

is controlled by installer sized/provided system loop circulator(s).

d. This piping arrangement can be used either for

space heating-only applications or space heating with indirect water heater(s) applications.

i. Space heating only - refer to Table 17 and

Figure 37 “Near Boiler Piping - Heating Only” as applicable.

ii. Space heating plus indirect water

heater(s) - refer to Table 17 and Figure 38

“Near Boiler Piping - Heating Plus Indirect Water Heater” as applicable.

NOTICE

Where it is not possible to install a separate boiler loop, the system circulator must be

sized to ensure that the ow through boiler stays within the dened parameters to prevent overheating when the boiler is red at it’s full rated input. Install a ow meter to measure the ow, or re the boiler at full rate and ensure the

boiler DT does not exceed 35°F.

103448-02 - 6/13 53

Page 54

VI. Water Piping and Trim B. Piping System To Be Employed (continued)

2. Direct connection of Alpine (ALP) boiler to heating system, similar to a conventional boiler, is

NOT RECOMMENDED because:

a. The ow rate through system must be the same

as through boiler and fall within limits specied

in Table 16.

b. Pressure drop through entire system must be

known, added to pressure drop through boiler,

and, a circulator selected to provide required

ow at total calculated pressure drop.

c. It is often very difcult to accurately calculate

the pressure drop through the system.

d. In replacement installations, it may be nearly

impossible to get an accurate measurement of

piping amount and number of ttings in the system. If system is zoned, the system ow rate

may drop well below recommended minimum

ow when only a single zone is calling for heat.

Table 16: Flow Range Requirement Through Boiler

Boiler Model

ALP080B 1 1 4.2 4.8 4.9 6.4 5.8 8.9 7.3 13.4 ALP105B 1 1 5.5 7.0 6.4 9.3 7.7 12.8 9.6 19.1 ALP150B 1 1 7.9 5.2 9.2 6.6 11.0 8.9 13.8 12.7 ALP210B 1 1 11.1 5.4 12.9 7.1 15.5 9.8 19.4 14.4 ALP285B 1¼ 1¼ 15.1 5.9 17.7 7.8 21.2 10.7 26.5 16.0

ALP399 1½ 1½ 21.5 6.1 25.1 7.9 30.2 10.8 37.7 15.9

Notes: Required Flow (GPM) = ** Output (MBH) x 1000/500 x DT

** Output (MBH) - Select Value for specic Boiler Model from Tables 2A or 2B

Using boiler antifreeze will result in higher uid density and may require larger circulators.

Boiler

Supply

Connection,

Inch, FPT

Boiler

Return

Connection,

Inch, FPT

Minimum

Required

Flow (GPM)

@ 35°F DT

Boiler

Head Loss,

Ft.

@ 35°F DT

Required

Flow,

(GPM)

@ 30°F DT

Boiler

Head Loss,

Ft.

@ 30°F DT

Required

Flow,

(GPM)

@ 25°F DT

Boiler

Head Loss,

Ft.

@ 25°F DT

Maximum

Required

Flow (GPM)

@ 20°F DT

Boiler

Head Loss,

@ 20°F DT

Ft.

Alpine Boiler Head Loss vs. Flow

105

150

210

285

399

Boiler Head Loss (Feet)

0 5 10 15 20 25 30 35 40 45 50

Flow Rate (GP M)

500

54 103448-02 - 6/13

Page 55

VI. Water Piping and Trim B. Piping System To Be Employed (continued)

3. Alpine boiler models ALP080B thru ALP285B are factory supplied with circulators, which were sized for near-boiler piping equivalent length of 50 ft. and listed temperature differential. See Table 17 for details.

It is the installer’s responsibility to insure a proper

installation and where applicable, proper circulator speed setting for the boiler circulator to achieve

a required ow rate. Where near-boiler piping

The 10th digit of the Alpine boiler part number indicates the brand of boiler circulator included with the boiler. A “T” in the 10th digit of the part number indicates a Taco circulator; a “G” indicates a Grundfos circulator. Example: Boiler part number: ALP105BW-2T02 indicates Alpine boiler equipped with Taco Circulator Boiler part number: ALP105BW-2G02 indicates Alpine boiler equipped with Grundfos Circulator

exceeds 50 equivalent feet, alternate circulator selection may be required.

Table 17: Recommended Circulator Models for Alpine (ALP) Boilers Based on Listed Temperature Differential

and 50 ft. Equivalent Length Near-Boiler Piping - Space Heating Circulator

Boiler

Model

ALP080B 1 1 1 1 7.3

ALP105B 1 1 1 1 7.7 14.3

ALP150B 1 1 1 1 11.0 11.7

ALP210B 1 1 1¼ 1¼ 15.5 11.7

ALP285B 1¼ 1¼ 1½ 1½ 21.5 12.3

ALP399 1½ 1½ 2 2 30.2 11.6

Notes:

(1)

(2)

(3)

When selecting Circulators other than recommended, contact Circulator Manufacturer for sizing information.

Boiler Supply

Connection,

Inch, FPT

Temperature Differential = 20°F

Taco Circulators shown are not equipped with internal ow check valve (IFC). Circulators are not supplied with boiler.

Near-Boiler Piping Size shown is based on 2 to 5.5 Ft/Sec. velocity range to avoid potential noise and pipe erosion.

Boiler

Return

Connection,

Inch, FPT

Near-Boiler

Piping

Supply Pipe

Size, Inch

Near-Boiler

Piping

Return Pipe

Size, Inch

Flow, GPM

@ 25°F

Temp.

Differential

(1)

Combined

Boiler &

Piping Loop

Head Loss, Ft.

14.7

Recommended

Circulator

Make & Model

Taco 0015 (Speed 3)

Grundfos UPS

15-58 FRC (Speed 2)

Taco 0015 (Speed 3)

Grundfos UPS

26-99 FC (Speed 1)

Taco 0015 (Speed 3)

Grundfos UP

26-99 FC (Speed 2)

Taco 0014

Grundfos UP

26-99 FC (Speed 2)

Taco 0011

Grundfos UP

26-99 FC (Speed 3)

Taco 2400-20

Grundfos UPS

26-150 F/SF (Speed 2)

(2)

(2) (3)

(2)

C. Standard Installation Requirements

Observe the following guidelines when making the

actual installation of the boiler piping:

1. Safety Relief Valve (Required) - The relief valve is

packaged loose with boiler and must be installed in the location shown in Figure 36 “Factory Supplied Piping and Trim Installation”. The relief valve must be installed with spindle in vertical position. Installation of the relief valve must comply with ASME Boiler and Pressure Vessel Code, Section IV. The standard factory

103448-02 - 6/13 55

shipped relief valve is rated for 30 PSI maximum working pressure for ALP080B thru ALP285B and 50 PSI for ALP399. 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 equal or exceeding the boiler DOE Heating Capacity (models ALP080B thru ALP285B) or the boiler AHRI Gross Output rating (model ALP399 only). Pipe the relief valve discharge to a location where hot water or steam will not create hazard or property damage if the valve opens. The end

Page 56

VI. Water Piping and Trim C. Standard Installation Requirements (continued)

Table 18: Fitting and Valve Equivalent Length

Copper Fitting and Sweat Valve

Equivalent Length (Ft)

Fitting or Valve Description

90° Elbow 2.5 3.0 4.0 5.5

45° Elbow 1.0 1.2 1.5 2.0

Tee (thru ow) 0.5 0.6 0.8 1.0

Tee (Branch ow) 4.5 5.5 7.0 9.0

Diverter Tee (typical) 23.5 25.0 23.0 23.0

Gate Valve 0.3 0.4 0.5 0.7

Globe Valve 25.0 36.0 46.0 56.0

Angle Valve 5.3 7.8 9.4 12.5

Ball Valve (standard port) 4.3 7.0 6.6 14.0

Ball Valve (full port) 1.9 1.4 2.2 1.3

Swing Check Valve 4.5 5.5 6.5 9.0

Flow-Check Valve (typical)

Buttery Valve 2.7 2.0 2.7 4.5

NOTE: Table 18 is provided as reference to assist in piping design and species equivalent length of typical piping ttings and

valves.

Copper Pipe or Valve Size

1 1¼ 1½ 2

54.0 74.0 57.0 177.0

Table 18: Fitting and Valve Equivalent Length

(cont’d)

Threaded Fitting and Valve Equivalent Length (Ft)

Fitting or Valve Description

90° Elbow 2.6 3.5 4.0 5.2

Long Radius

Elbow (45° or 90°)

Tee (thru ow) 1.8 2.3 2.7 3.5

Tee (Branch ow) 5.3 6.9 8.1 10.0

Close Return Bend 4.4 5.8 6.7 8.6

Gate Valve (full open) 0.7 0.9 1.1 1.4

Globe Valve (full open) 30.0 39.0 46.0 59.0

Angle Valve (full open) 13.0 17.0 20.0 26.0

Swing Check Valve (full open)

Flow-Check Valve (typical)

Black Threaded Pipe or

Valve Size

1 1¼ 1½ 2

1.4 1.8 2.2 2.8

8.7 12.0 13.0 17.0

42.0 60.0 63.0 83.0

NOTICE

The Alpine (ALP) boiler heat exchanger is made from stainless steel tubular coil having relatively narrow

waterways. Once lled with water, it will be subject to the effects of corrosion. Failure to take the following

precautions to minimize corrosion and heat exchanger waterways overheating could result in severe boiler damage.

•

Before connecting the boiler, insure the system is free of impurities, grease, sediment, construction

dust, sand, copper dust, ux and any residual boiler water additives. Flush the system thoroughly and

repeatedly, if needed, with clear water mixed with concentrated rinse agent to remove these contaminants completely.

•

Iron oxide (red oxide sludge Fe2O3) is produced during oxygenation. To minimize any oxygen presence in the system, the system must be air free and leak tight. Do not connect the boiler to radiant tubing

without an oxygen barrier. Using automatic water rell is not recommended, however, if such rell is employed, a water meter must be added to evaluate the makeup water volume taken after initial ll and

eliminate any water leakage as early as possible.

•

Maintain the water pressure in the boiler at a minimum of 12 PSI.

•

The boiler water pH must be within 7.5 < pH < 9.5. If the system contains any aluminum components, pH must be less than 8.5.

•

Black oxide sludge (magnetite Fe3O4) forms as the result of continuous electrolytic corrosion in any system not protected by an inhibitor.

•

Scale deposit is made up of lime scale contained in most distributed water and settles over the warmest

surfaces of boiler heat exchanger causing subsequent overheating and eventual failure. Water hardness

must be maintained within 3 to 9 grain/gal range.

•

Refer to Section XI “Service and Maintenance” for recommended heating system water treatment products (corrosion/scale inhibitors, cleaners etc) and their suppliers.

56 103448-02 - 6/13

Page 57

CAUTION

It is the installers responsibility to select pumps

and boiler piping congurations that provide the

proper ow rates and performance for the boiler

and indirect water heater.

Refer to Table 17 for recommended Boiler Loop

Circulator.

VI. Water Piping and Trim C. Standard Installation Requirements (continued)

103448-02 - 6/13 57

Figure 37: Near Boiler Piping - Heating Only

Page 58

CAUTION

It is the installers responsibility to select pumps

and boiler piping congurations that provide the

proper ow rates and performance for the boiler

and indirect water heater.

Refer to Table 17 for recommended Boiler Loop

Circulator.

VI. Water Piping and Trim C. Standard Installation Requirements (continued)

58 103448-02 - 6/13

Figure 38: Near Boiler Piping - Heating Plus Indirect Water Heater

Page 59

VI. Water Piping and Trim C. Standard Installation Requirements (continued)

of the discharge pipe must terminate in an unthreaded pipe. If the relief valve is not piped to a drain, it must

terminate at least 6” above the oor. Do not run relief

valve discharge piping through an area prone to freezing. The termination of discharge piping must be in an area where it will not become plugged by debris.

WARNING

Safety relief valve discharge piping must be piped such that the potential of severe burns is eliminated. DO NOT pipe in any area where freezing could occur. DO NOT install any shut-off valves, plugs or caps. Consult Local Codes for proper discharge piping arrangement.

2 Circulator (Required) – Usually at least two

circulators will be required to properly install a Alpine™ Series boiler. See Paragraph B above for information on sizing the circulators.

3. Expansion Tank (Required) – If this boiler is

replacing an existing boiler with no other changes in the system, the old expansion tank can generally be reused. If the expansion tank must be replaced, consult the expansion tank manufacturer’s literature for proper sizing.

4. Fill Valve (Required) – Either manual

(recommended) or automatic ll valve may be used. However, if automatic rell is employed, a water

meter must be added to evaluate the makeup water

volume taken after initial ll and eliminate any

water leakage as early as possible.

5. Automatic Air Vent (Required) –At least one

automatic air vent is required. Manual vents will usually be required in other parts of the system to

remove air during initial ll.

6. Manual Reset High Limit (Required by some

Codes) – This control is required by ASME CSD-1

and some other codes. Install the 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 43 and 45A in Section VIII Electrical.

7. Flow Control Valve (Strongly Recommended) –

The ow control valve prevents ow through the

system unless the circulator is operating. Flow control valves are used to prevent gravity circulation

or “ghost ows” in circulator zone systems through

zones that are not calling for heat.

8. Y-strainer (Recommended) – A Y-strainer or

equivalent strainer removes heating system debris from hydronic systems and protects boiler heat exchanger from fouling up. Install the strainer downstream of full port isolation valve, at the inlet side of the circulator, for easy service.

9. Isolation Valves (Strongly recommended) – Isolation valves are useful when the boiler must be drained, as they will eliminate having to drain and

rell the entire system.

10. Drain Valve (Required) – Drain valve is packaged loose with boiler and must be installed in the location shown in Figure 36 “Factory Supplied Piping and Trim Installation” of the Installation, Operating and Service Instructions.

11. Low Water Cutoff (Required by some Codes) –

LWCO with harness is available as optional kit.

Order Complete Kit (Part Number 102097-01) when required.

D. Special Situation Installation Requirements

Observe the following guidelines when making the

actual installation of the boiler piping for special situations:

1. Systems containing high level of dissolved oxygen – Many hydronic systems contain enough dissolved oxygen to cause severe corrosion damage to Alpine (ALP) boiler heat exchanger. Some examples include but not limited to:

• Radiant systems employing tubing without

oxygen barrier

• Systems with routine additions of fresh water

• Systems open to atmosphere

If the boiler is used in such a system, it must be

separated from oxygenated water being heated with a heat exchanger as shown in Figure 39. Consult the heat exchanger manufacturer for proper heat

exchanger sizing as well as ow and temperature

requirements. All components on the oxygenated side of the heat exchanger, such as the pump and expansion tank, must be designed for use in oxygenated water.

2. Piping with a Chiller - If the boiler is used in conjunction with a chiller, pipe the boiler and chiller in parallel. Use isolation valves to prevent chilled water from entering the boiler.

Table 19: Multiple Boiler Water Manifold Sizing

Number of Boilers

Boiler Model

ALP080B 1¼” 1½” 1½” 2” 2” 2” 2½” ALP105B 1¼” 1½” 2” 2” 2½” 2½” 2½” ALP150B 1½” 2” 2½” 3” 3” 3” 3” ALP210B 2” 2½” 2½” 3” 3½” 3½” 3½” ALP285B 2” 3” 3” 3½” 4” 4” 5”

ALP399 2½” 3” 3” 4” 5” 5” 5”

2 3 4 5 6 7 8

Recommended Minimum Common Water

Manifold Size (NPT)

103448-02 - 6/13 59

Page 60

VI. Water Piping and Trim E. Multiple Boiler Installation Water Piping (continued)

Figure 39: Isolation of the Boiler From Oxygenated Water with A Plate Heat Exchanger

3. Boiler Piping with Air Handlers - Where the boiler is connected to air handlers through which

refrigerated air passes, use ow control valves in the

boiler piping or other automatic means to prevent gravity circulation during the cooling cycle.

E. Multiple Boiler Installation Water Piping – (See

Table 19 and Figures 40B and 41B)

1. Refer to this Section of this manual for:

a. Installation of Factory Supplied Piping and Trim

Components for an individual module (boiler).

b. Regarding an individual module (boiler) piping

system specic details.

c. Selection criteria for individual module (boiler)

space heating and/or DHW circulators.

2. For installations where indirect domestic hot water heater is combined with space heating, when sizing an indirect water heater circulator, compare the

specied ow range through an Alpine model boiler

to an indirect water heater (Alliance SL™) model

coil ow rate required to achieve water heater

rating. Refer to Table 20 and Figures 41A and 41B.

a. When Alliance SL™ model coil ow rate,

required to achieve water heater rating, falls within the specied ow range for Alpine boiler model, the Alliance SL™ model can be piped as part of Alpine near-boiler piping. Refer to Table 20 and Figures 41A and 41B.

b. When Alliance SL™ model coil ow rate,

required to achieve water heater rating, exceeds the specied ow range for Alpine boiler model, the Alliance SL™/Alpine boiler combination may result in excessive noise and boiler heat exchanger erosion, and therefore, is not recommended. Refer to Table 20 and Figures 41A and 41B for details.

c. When Alliance SL™ model coil ow rate,

required to achieve water heater rating, falls below the specied ow range for Alpine boiler model, the Alliance SL™ model must be piped

as a separate heating zone off the system

header. The circulator must be sized based on

the Alliance SL™ model coil ow and combined

coil pressure drop and the zone piping total equivalent length. Refer to Table 20 and Figures 41A and 41B for details.

60 103448-02 - 6/13

Page 61

VI. Water Piping and Trim E. Multiple Boiler Installation (continued)

103448-02 - 6/13 61

Figure 40A: 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 and

may be required by Local Codes.

Page 62

VI. Water Piping and Trim E. Multiple Boiler Installation (continued)

62 103448-02 - 6/13

Figure 40B: Multiple Boiler Water Piping w/Domestic Hot Water Heater (Page 2 of 2)

NOTICE

Installing a low water cutoff in the system piping

of multiple boilers is strongly recommended and

may be required by Local Codes.

Page 63

CAUTION

It is the installers responsibility to select pumps

and boiler piping congurations that provide the

proper ow rates and performance for the boiler

and indirect water heater.

Refer to Table 17 for recommended Boiler Loop

VI. Water Piping and Trim E. Multiple Boiler Installation (continued)

103448-02 - 6/13 63

Circulator.

Figure 41A: Alternate Multiple Boiler Water Piping w/ Indirect Domestic Hot Water Heater (Page 1 of 2)

Page 64

CAUTION

It is the installers responsibility to select pumps

and boiler piping congurations that provide the

proper ow rates and performance for the boiler

and indirect water heater.

Refer to Table 20 for recommended Boiler Loop

Circulator.

VI. Water Piping and Trim E. Multiple Boiler Installation (continued)

64 103448-02 - 6/13

Figure 41B: Alternate Multiple Boiler Water Piping w/Indirect Domestic Hot Water Heater (Page 2 of 2)

Page 65

Notes

Figure

Reference

as Part of

Circulator

*Recommended

Make & Model for

Alliance SL installed

Boiler,

& Piping

Combined

Alliance

Alliance SL

Loop Head

Alliance SL

Head

SL Coil

Required

Loss, Ft @

Coil

Required

Flow Rate,

Models to

As Part of

Near-Boiler

be installed

41B

Taco 0014

FC (second speed)

Near-Boiler Piping

Grundfos UPS26-99

Loss, Ft

Flow Rate

GPM

SL27 6 9 19.3

SL35 6 9 19.3

SL50 6 9.5 19.8

Piping

SL70 6 10 20.3

41B

Taco 0014

Grundfos UPS26-99

SL27 6 9 19.3

SL35 6 9 19.3

SL119 14 17 NA Not Recommended NA Note 1

NA Note 1

41B Note 2

FC (second speed)

NA Not Recommended

SL50 6 9.5 19.8

SL70 6 10 20.3

SL27 6 9

SL35 6 9

SL119 14 17

SL50 6 9.5

41B

(max speed)

Taco 1400-45

Grundfos UPS 32-80/2

SL70 6 10

SL119 14 17 36

GPM

Boiler,

@ 35°F

Flow thru

Min Req’d

GPM

Flow,

@ 25°F

Max

Boiler,

GPM @

20°F DT

Flow thru

Allowable

Inch

Pipe

Piping

Return

Pipe

Piping

Supply

Return

Inch, FPT

Connection,

Supply

Inch, FPT

Connection,

Boiler

Model

Size,

Inch

Size,

ALP080B 1 1 1 1 7.3 5.8 4.2

Near-

Boiler

Near-

Boiler

VI. Water Piping and Trim E. Multiple Boiler Installation (continued)

Table 20: Recommended Circulator Models for Alpine (ALP) Boilers and Alliance SL Indirect Water Heaters

Installed as Part of Near-Boiler Piping Up to 75 Ft. Equivalent Length - Domestic Hot Water Circulator

ALP105B 1 1 1 1 9.6 7.7 5.5

ALP150B 1 1 1 1 13.8 11 7.9

NOTES:

Note 1: Required Alliance SL Coil Flow Rate exceeds Max Allowable Flow Rate thru Boiler; this Boiler/Alliance SL combination may result in boiler heat exchanger erosion and noise.

Note 2: Required Alliance SL Coil Flow Rate is below Min Required Flow Rate thru Boiler; this Model can only be installed as separate heating zone off system header - see Figure 40A for alternate

IWH piping. Indirect Water Heater Circulator must be selected by an installer based on Alliance SL required coil ow and corresponding coil head loss shown as well as total equivalent length of

such separate zone.

Note 3: Combined Head Loss shown corresponds to Min Required Flow Rate thru Boiler.

* Circulator Models shown are not equipped with internal ow check valve (IFC).

When selecting Circulators with IFC contact Circulator Manufacturer for sizing information.

Near-Boiler Piping Size shown is based on 2 to 5.5 Ft/sec velocity range to avoid potential noise and pipe erosion.

103448-02 - 6/13 65

Page 66

Notes

Figure

Reference

Model for

Alliance SL

*Recommended

Circulator Make &

Boiler,

Combined

SL Coil

Alliance

Models to

Alliance SL

of Near-Boiler

installed as Part

& Piping

Loop Head

Alliance SL

Head

Required

Loss, Ft @

Coil

Required

Flow Rate,

As Part of

Near-Boiler

be installed

Piping

Loss, Ft

Flow Rate

GPM

SL27 6 9

Piping

NA Not Recommended 41B Note 2

SL35 6 9

SL50 6 9.5

SL70 6 10

41B

Taco 1400-45

80/2 (max speed)

Grundfos UPS 32-

SL35 6 9

SL27 6 9

SL119 14 17 29.7

NA Not Recommended 41B Note 2

SL50 6 9.5

41B Note 3

Taco 1400-45

80/2 (max speed)

Grundfos UPS 32-

SL70 6 10

SL119 14 17.0 27.0

NA Not Recommended 41B Note 2

SL35 6 9

SL50 6 9.5

SL27 6 9

SL70 6 10

SL119 14 17.0

Boiler,

Flow thru

Min Req’d

GPM

Flow,

Max

Flow thru

Allowable

Near-

Boiler

Piping

Near-

Boiler

Piping

Boiler

Return

Boiler

Supply

GPM

@ 35°F

@ 25°F

Boiler,

GPM @

20°F DT

Inch

Pipe

Size,

Return

Inch

Pipe

Size,

Supply

Inch, FPT

Connection,

Inch, FPT

Connection,

VI. Water Piping and Trim E. Multiple Boiler Installation (continued)

Table 20 (continued): Recommended Circulator Models for Alpine (ALP) Boilers and Alliance SL Indirect Water Heaters

Installed as Part of Near-Boiler Piping Up to 75 Ft. Equivalent Length - Domestic Hot Water Circulator

Boiler

Model

66 103448-02 - 6/13

ALP210B 1 1 1-1/4 1-1/4 19.4 15.5 11.1

ALP285B 1-1/4 1-1/4 1-1/2 1-1/2 26.5 21.2 15.1

ALP399 1-1/2 1-1/2 2 2 37.7 30.2 21.5

NOTES:

Note 1: Required Alliance SL Coil Flow Rate exceeds Max Allowable Flow Rate thru Boiler; this Boiler/Alliance SL combination may result in boiler heat exchanger erosion and noise.

Note 2: Required Alliance SL Coil Flow Rate is below Min Required Flow Rate thru Boiler; this Model can only be installed as separate heating zone off system header - see Figure 40A for alternate IWH

piping. Indirect Water Heater Circulator must be selected by an installer based on Alliance SL required coil ow and corresponding coil head loss shown as well as total equivalent length of such

separate zone.

Note 3: Combined Head Loss shown corresponds to Min Required Flow Rate thru Boiler.

* Circulator Models shown are not equipped with internal ow check valve (IFC).

When selecting Circulators with IFC contact Circulator Manufacturer for sizing information.

Near-Boiler Piping Size shown is based on 2 to 5.5 Ft/sec velocity range to avoid potential noise and pipe erosion.

Page 67

VII. Gas Piping

contact gas supplier for additional information.

WARNING

Failure to properly pipe gas supply to boiler may result in improper operation and damage to the boiler or structure. Always assure gas piping is absolutely leak free and of the proper size and type for the connected load.

An additional gas pressure regulator may be needed. Consult gas supplier.

Size corrugated stainless steel tubing (CSST)

to ensure proper capacity and minimize ow

restrictions. Use two wrenches when tightening gas

piping at boiler, using one wrench to prevent the boiler gas valve from turning. Failure to support the boiler gas valve to prevent it from turning could damage gas valve components.

A. Size gas piping. Design system to provide adequate gas

supply to boiler. Consider these factors:

1. Allowable pressure drop from point of delivery to boiler. Maximum allowable system pressure is ½ psig. Actual point of delivery pressure may be less;

Table 21A: Maximum Capacity of Schedule 40 Black Pipe in CFH* (Natural Gas) For Gas Pressures of 0.5 psig or Less

Inlet Pressure 0.5 PSI or less; 0.3 Inch W.C. Pressure Drop

Nominal Pipe

Size, In.

½ 0.622 131 90 72 62 55 50 46 42 40 38

¾ 0.824 273 188 151 129 114 104 95 89 83 79

1 1.049 514 353 284 243 215 195 179 167 157 148

1¼ 1.380 1056 726 583 499 442 400 368 343 322 304

1½ 1.610 1582 1087 873 747 662 600 552 514 482 455

2 2.067 3046 2094 1681 1439 1275 1156 1063 989 928 877

2½ 2.469 4856 3337 2680 2294 2033 1842 1695 1576 1479 1397

3 3.068 8584 5900 4738 4055 3594 3256 2996 2787 2615 2470

Nominal Pipe

Size, In.

½ 0.622 172 11 8 95 81 72 65 60 56 52 50

¾ 0.824 360 247 199 170 151 137 126 117 11 0 104

1 1.049 678 466 374 320 284 257 237 220 207 195

1¼ 1.380 1392 957 768 657 583 528 486 452 424 400

1½ 1.610 2085 1433 1151 985 873 791 728 677 635 600

2 2.067 4016 2760 2217 1897 1681 1523 1402 1304 1223 1156

2½ 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 your gas supplier for the actual heating value of your

gas.

Inside

Diameter, In.

Inside

Diameter, In.

10 20 30 40 50 60 70 80 90 100

Inlet Pressure 0.5 PSI or less; 0.5 Inch W.C. Pressure Drop

10 20 30 40 50 60 70 80 90 100

For materials or conditions other than those listed

Minimum gas valve inlet pressure is stamped on the rating label located in the boiler’s vestibule compartment.

2. Maximum gas demand. Refer to the boiler’s input as printed on its rating label. Also consider existing and expected future gas utilization equipment (i.e. water heater, cooking equipment).

3. Length of piping and number of ttings. Refer

to Tables 21A (natural gas) or 21B (LP gas) for maximum capacity of Schedule 40 pipe. Table 22

lists equivalent pipe length for standard ttings.

4. Specic gravity of gas. Gas piping systems for gas with a specic gravity of 0.60 or less can be sized

directly from Tables 21A or 21B, unless authority

having jurisdiction species a gravity factor be applied. For specic gravity greater than 0.60, apply gravity factor from Table 23. If exact specic

gravity is not shown choose next higher value.

above, refer to National Fuel Gas Code, NFPA54/ ANSI Z223.1, and/or CAN/CSA B149.1 Natural Gas and Propane Installation Code. or size system using standard engineering methods acceptable to authority having jurisdiction.

Length of Pipe, Ft.

103448-02 - 6/13 67

Page 68

VII. Gas Piping (continued)

Table 21B: Maximum Capacity of Schedule 40 Black Pipe in CFH* (LP Gas) For Gas Pressures of 0.5 psig or Less

Inlet Pressure 11.0 Inch W.C.; 0.3 Inch W.C. Pressure Drop

Nominal

Pipe Size, In.

½ 0.622 88 60 48 41 37 33 31 29 27 25

¾ 0.824 184 126 101 87 77 70 64 60 56 53

1 1.049 346 238 191 163 145 131 121 112 105 100

1¼ 1.380 710 488 392 336 297 269 248 231 216 204

1½ 1.610 1064 732 588 503 446 404 371 346 324 306

2 2.067 2050 1409 1131 968 858 778 715 666 624 590

2½ 2.469 3267 2246 1803 1543 1368 1239 1140 1061 995 940

3 3.068 5776 3970 3188 2729 2418 2191 2016 1875 1760 1662

Nominal

Pipe Size, In.

½ 0.622 116 80 64 55 48 44 40 38 35 33

¾ 0.824 242 166 134 114 101 92 85 79 74 70

1 1.049 456 314 252 215 191 173 159 148 139 131

1¼ 1.380 937 644 517 442 392 355 327 304 285 269

1½ 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

2½ 2.469 4308 2961 2377 2035 1803 1634 1503 1399 1312 1239

3 3.068 7615 5234 4203 3597 3188 2889 2658 2472 2320 2191

Inside

Diameter, In.

Inside

Diameter, In.

Length of Pipe, Ft.

10 20 30 40 50 60 70 80 90 100

Inlet Pressure 11.0 Inch W.C.; 0.5 Inch W.C. Pressure Drop

Length of Pipe, Ft.

10 20 30 40 50 60 70 80 90 100

* 1 CFH of LP Gas is approximately equal to 2.5 MBH; contact your gas supplier for the actual heating value

of your gas.

Table 22: Equivalent Lengths of Standard Pipe Fittings & Valves

Nominal

Pipe Size,

Inc.

½ 0.622 0.4 17.3 8.7 4.3 0.7 1.6 3.5 1.6 3.1

¾ 0.824 0.5 22.9 11.4 5.7 1.0 2.1 4.6 2.1 4.1

1 1.049 0.6 29.1 14.6 7.3 1.2 2.6 5.8 2.6 5.2

1¼ 1.38 0.8 38.3 19.1 9.6 1.6 3.5 7.7 3.5 6.9

1½ 1.61 0.9 44.7 22.4 11.2 1.9 4.0 9.0 4.0 8.0

2 2.067 1.2 57.4 28.7 14.4 2.4 5.2 11.5 5.2 10.3

2½ 2.469 1.4 68.5 34.3 17.1 2.9 6.2 13.7 6.2 12.3

3 3.068 1.8 85.2 42.6 21.3 3.6 7.7 17.1 7.7 15.3

Inside

Diameter,

In.

Valves (Screwed) - Fully Open Screwed Fittings

180 Close

Return

Bend

Flow Thru

Gate Globe Angle

Swing Check

45°

Elbow

90°

Elbow

90 Tee

Run

90 Tee, Flow Thru Branch

68 103448-02 - 6/13

Page 69

VII. Gas Piping (continued)

Table 23: Specic Gravity Correction Factors

Specic

Gravity

0.60 1.00 0.90 0.82

0.65 0.96 1.00 0.78

0.70 0.93 1.10 0.74

0.75 0.90 1.20 0.71

0.80 0.87 1.30 0.68

0.85 0.81 1.40 0.66

Correction

Factor

Specic

Gravity

Correction

Factor

B. Connect boiler gas valve to gas supply system.

CAUTION

The gas valve and blower will not support the weight of the piping. Do not attempt to support the weight of the piping with the boiler gas valve.

Ensure that the high gas pressure regulator is at least 6 to 10 feet upstream of the boiler.

It is very important that the gas line is properly purged by the gas supplier or utility company.

WARNING

Failure to use proper thread compounds on all

gas connectors may result in leaks of ammable

gas.

3. Alpine (ALP) boilers have factory supplied Miscellaneous Part Carton (P/N 101777-01 ALP080B thru ALP210B; 101777-02 - ALP285B; 1012942-03 - ALP399), which includes gas piping components to connect boiler gas valve to gas supply system. Install these components prior to connecting boiler to gas supply system piping as follows:

a. Locate and remove either ½” NPT x 6” long

black nipple and ½” NPT external gas shutoff valve (ALP080B thru ALP210B), or ¾” NPT x 6” long black nipple and ¾” NPT external gas shutoff valve (ALP285B thru ALP399).

b. Feed the appropriate nipple through factory

installed jacket left side panel grommet (refer to Figure 1A or 1B for gas supply connection

identication) and screw the nipple into boiler

gas valve inlet port.

c. Mount the appropriate external gas shutoff valve

onto the threaded nipple end outside of the jacket left side panel.

d. Install sediment trap, ground-joint union and

manual shut-off valve upstream of mounted factory supplied manual shut-off valve. See Figure 42.

4. All above ground gas piping upstream from manual shut-off valve must be electrically continuous and bonded to a grounding electrode. Do not use gas piping as grounding electrode. Refer to National Electrical Code, NFPA 70.

WARNING

Gas supply to boiler and system must be absolutely shut off prior to installing or servicing boiler gas piping.

1. Use methods and materials in accordance with local plumbing codes and requirements of gas supplier. In absence of such requirements, follow National Fuel Gas Code, NFPA 54/ANSI Z223.1, and/or CAN/ CSA B149.1 Natural Gas and Propane Installation Code.

2. Use thread (joint) compounds (pipe dope) resistant

to action of liqueed petroleum gas.

Figure 42: Recommended Gas Piping

103448-02 - 6/13 69

Page 70

VII. Gas Piping (continued)

C. Pressure test. See Table 24 for Alpine Min./Max.

Pressure Ratings. The boiler and its gas connection must be leak tested before placing boiler in operation.

1. Protect boiler gas control valve. For all testing over ½ psig, boiler and its individual shutoff valve must be disconnected from gas supply piping. For testing at ½ psig or less, isolate boiler from gas supply piping by closing boiler’s individual manual shutoff valve.

2. Locate leaks using approved combustible gas noncorrosive leak detector solution.

Table 24: Min./Max. Pressure Ratings

LP Gas

Min.

Pressure

Inlet to Gas

Valve

(in. w.c.)

Boiler Model

No.

ALP080B

ALP105B

ALP150B

ALP210B

ALP285B

ALP399

Natural/LP

Gas Max.

Pressure

(in. w.c.)

14 4.0 11.0

Natural Gas

Min. Pressure

Inlet to Gas

Valve

(in. w.c.)

D. Gas Piping for Multiple Boiler Installation

1. Individual module (boiler) gas pipe sizing specic

details – see paragraph A.

2. Individual module (boiler) recommended gas piping detail - see Figure 42.

3. An additional gas pressure regulator(s) may need to be to installed to properly regulate inlet gas pressure at the smallest individual module (boiler).

DANGER

Do not use matches, candles, open ames or

other ignition source to check for leaks.

WARNING

If gas pressure in the building is above ½ psig,

an 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 pressure at the input of the smallest boiler. If the regulator cannot do this, two or

more additional regulators are required. Consult

regulator manufacturer and/or local gas supplier

for instructions and equipment ratings.

70 103448-02 - 6/13

Page 71

VIII. Electrical

DANGER

Positively assure all electrical connections are unpowered before attempting installation or service of electrical components or connections of the boiler or building. Lock out all electrical boxes with padlock once power is turned off.

WARNING

Failure to properly wire electrical connections to the boiler may result in serious physical harm.

Electrical power may be from more than one source. Make sure all power is off before attempting any electrical work.

Each boiler must be protected with a properly sized over-current device.

Never jump out or make inoperative any safety or operating controls.

The wiring diagrams contained in this manual are for reference purposes only. Each boiler is shipped with a wiring diagram attached to the front door. Refer to this diagram and the wiring diagram of any controls used with the boiler. Read, understand and follow all wiring instructions supplied with the controls.

IMPORTANT

This boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases. This feature is equipped with an override which is provided primarily to permit the

use of an external energy management system that serves the same function. THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE:

• An external energy management system is installed that 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 300,000 BTU/hr or

greater.

• This boiler is equipped with a tankless coil.

This notice applies to Models ALP080B through ALP285B Only (does not apply to ALP399).

NOTICE

This boiler is equipped with a high water temperature limit located inside the internal wiring of the boiler.

This limit provides boiler shutdown in the event the boiler water temperature exceeds the set point of the

limit control. Certain Local Codes require an additional water temperature limit. In addition, certain types

of systems may operate at temperatures below the minimum set point of the limit contained in the boiler.

If this occurs, install an additional water temperature limit (Honeywell L4006 Aquastat). Wire as indicated in

the Electrical Section of this manual.

NOTICE

All wire, wire nuts, controls etc. are installer supplied unless otherwise noted.

A. General. Install wiring and electrically ground boiler

in accordance with authority having jurisdiction or, in the absence of such requirements, follow the National Electrical Code, NFPA 70, and/or CSA C22.1 Electrical

Code.

B. A separate electrical circuit must be run from

the main electrical service with an over-current device/disconnect in the circuit. A service switch is

103448-02 - 6/13 71

recommended and may be required by some local jurisdictions. Install the service switch in the line voltage “Hot” leg of the power supply. Locate the service switch such that the boiler can be shut-off without exposing personnel to danger in the event of an emergency. Connect the main power supply and ground to the three (3) boiler wires (black, white and green) located in the junction box at the inside top of the boiler jacket.

Page 72

VIII. Electrical (continued)

72 103448-02 - 6/13

Page 73

VIII. Electrical (continued)

103448-02 - 6/13 73

Figure 43: Wiring Connections Diagram

Page 74

VIII. Electrical (continued)

C. Refer to Figures 43 and 44 or details on the internal

boiler wiring.

Line Voltage (120 VAC) Connections - see Figure 43.

1. The line voltage connections are located in the junction box on the left side of the vestibule. The terminal block TB-1 in conjunction with terminal

screw identication label is attached to the junction

box combination cover/inside high voltage bracket.

2. The conductor insulation colors are:

a. Black – L1 line voltage “Hot” b. White – L2 line voltage “Neutral” for boiler and

circulators

c. Red – Line voltage “Hot” for “Heating”

circulator, “System” circulator and “DHW” circulator

d. Green – Ground connection

Low Voltage (24 VAC) Connections - see Figure 43.

3. The terminal block TB-2 in conjunction with

terminal screw identication label is attached to

the junction box front and located inside Control compartment on the left side.

4. The connections are (listed identication label top to

bottom):

a. 1 – “Heating Thermostat”

b. 2 – “Heating Thermostat”

c. 3 – “DHW Temperature Switch”

d. 4 – “DHW Temperature Switch”

e. 5 – “Outdoor Sensor”

f. 6 – “Outdoor Sensor”

g. 7 – “Header Sensor”

h. 8 – “Header Sensor”

i. 9 – “Remote Firing Rate”

j. 10 – “Remote Firing Rate”

k. 11 – “External Limit”

l. 12 – “External Limit”

5. If the outdoor sensor is connected to terminals 5 and 6 “Outdoor Sensor”, the boiler will adjust the target space heating set point supply water temperature downwards as the outdoor air temperature increases. If used, this sensor should be located on the outside of the structure in an area where it will sense the average air temperature around the house. Avoid placing this sensor in areas where it may be covered with ice or snow. Locations where the sensor will pick up direct radiation from the sun should also be avoided. Avoid placing the sensor near potential sources of electrical noise such as transformers,

power lines, and uorescent lighting. Wire the

sensor to the boiler using 22 gauge or larger wire.

As with the sensor, the sensor wiring should be routed away from sources of electrical noise. Where it is impossible to avoid such noise sources, wire the sensor using a 2 conductor, UL Type CM, AWM Style 2092, 300Volt 60°C shielded cable. Connect one end of the shielding on this cable to ground.

Table 25: Boiler Current Draw

Model Number

ALP080B <2

ALP105B <2

ALP150B <2

ALP210B <3

ALP285B <5

ALP399 <5

Nominal Current

(amps)

WARNING

When making low voltage connections, make sure that no external power source is present in the thermostat or limit circuits. If such a power source is present, it could destroy the boiler’s Microprocessor Control. One example of an external power source that could be inadvertently connected to the low voltage connections is a transformer in old thermostat wiring.

D. Power Requirements

Nominal boilers current draw is provided in Table

25. These values are for planning purposes only and represent only the boiler’s power consumption. To obtain total system power consumption add any selected circulator and component current draws.

E. Multiple Boiler Wiring

Install over-current protection in accordance with

authority having jurisdiction or, in the absence of such requirements, follow the National Electric Code, NFPA 70, and/or CSA C22.1 Electrical Code. Do not provide over-current protection greater than 15 amperes. If it becomes necessary to provide greater amperes (because of the number of boilers provided) use separate circuits and over-current protection for additional boilers.

F. External Multiple Boiler Control System

As an alternate to the Control internal sequencer,

the Control also accepts an input from an external sequencer. Follow multiple boiler control system manufacturer (Honeywell, Tekmar, etc.) instructions to properly apply a multiple boiler control system. The Tekmar Model 264 and Model 265 based control wiring diagrams (Figure 47A and 47B) are provided as examples of typical multiple boiler control systems.

74 103448-02 - 6/13

Page 75

VIII. Electrical (continued)

Figure 44: Ladder Diagram

103448-02 - 6/13 75

Page 76

VIII. Electrical (continued)

Figure 45A: Modied Wiring For DHW Priority When Using Low Flow Circulator Piped Off System Header -

Heating (with Central Heating Circulators) Plus Alternately Piped Indirect Water Heater

76 103448-02 - 6/13

Page 77

ALVES)

(SEE NOTE)

AT 0.9 AMPS (40VA REQ'D

W/ HEAT ANTICIPATOR SET

2 WIRE (24V) THERMOSTATS

FOR EVERY 3 ZONE VALVES)

TACO ZONE VALVES

AT 0.5 AMPS (40VA REQ'D

W/ HEAT ANTICIPATOR SET

2 WIRE (24V) THERMOSTATS

FOR EVERY 4 ZONE V

ZONE VALVES

HONEYWELL V8043E

AT 0.3 AMPS (40VA REQ'D

W/ HEAT ANTICIPATOR SET

2 WIRE (24V) THERMOSTATS

FOR EVERY 4 ZONE VALVES)

ZONE VALVES

#1361-102

WHITE ROGERS

231

FIELD INSTALLED

(SEE NOTE)

40VA TRANSFORMER

YE YE

(SEE NOTE)

FLAIR "VJ"

ZONE VALVES

AT 0.9 AMPS (40VA REQ'D

W/ HEAT ANTICIPATOR SET

2 WIRE (24V) THERMOSTATS

POWER

SUPPLY

120/60/1

TO SAGE2

HEATING T-STAT

4 5

FOR EVERY 6 ZONE VALVES)

Figure 45B: Modied Wiring For DHW Priority When Using Low Flow Circulator Piped Off System Header -

SEPARATE GROUND IS MADE IN THE ZONE CIRCUIT.

GROUNDED ON EI AND CANADIAN MODELS AND THE ZONE CIRCUIT MAY NOT OPERATE IF A

CORRECT BY SWITCHING X1 AND X2 OR X3 AND X4. ALSO, BOILER SECONDARY SIDE (24V) IS

TRANSFORMER ON TACO AND FLAIR ZONE VALVE CIRCUITS. IF CROSS-PHASING OCCURS,

CHECK FOR CROSS-PHASING BETWEEN BOILER TRANSFORMER AND FIELD SUPPLIED

NOTE:

VIII. Electrical (continued)

103448-02 - 6/13 77

Heating (with Central Heating Zone Valves) Plus Alternately Piped Indirect Water Heater

Page 78

Figure 46: Multiple Boiler Wiring Diagram

Internal Sage2.1 Multiple Boiler Control Sequencer

(Three Boilers Shown, Typical Connections for up to Eight Boilers)

VIII. Electrical (continued)

78 103448-02 - 6/13

Page 79

VIII. Electrical (continued)

Sequence of Operation

Tekmar 265 Based Control System (or equal)

Figure 47A: Multiple Boiler Wiring Diagram w/Tekmar 265 Control

The Tekmar 265 Control (or equal) can control up to three (3) boilers and an Indirect Water Heater. When a call for heat is received by the Tekmar 265 Control, the control

will re either one or more boilers in either parallel or sequential ring mode to establish a required reset water temperature in the system supply main based on outdoor

temperature. The boilers will modulate based on an Analog communication signal established between the Tekmar 265 Control and each boiler’s Sage2.1™ 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 for Indirect Hot Water is generated to the

Tekmar 265, the control will de-energize the zone pump control (ZC terminal), energize the Indirect pump and modulate the boiler ring to establish a setpoint temperature in

the main for the Indirect Heater using Priority. The Tekmar 265 also controls each boiler’s pump and a post purge of leftover temperature in the boilers will occur at the end of

the call for Indirect Hot Water.

103448-02 - 6/13 79

Page 80

Sequence of Operation

Tekmar 264 Based Control System (or equal)

Figure 47B: Multiple Boiler Wiring Diagram w/Tekmar 264 Control

VIII. Electrical (continued)

80 103448-02 - 6/13

The Tekmar 264 Control (or equal) can control up to four (4) boilers and an Indirect Water Heater by utilizing stage ring. When a call for heat is received by the Tekmar 264

Control, the control will re either one or more boilers in sequential ring mode to establish a required reset water temperature in the system supply main based on outdoor

temperature. The boilers will modulate on their own based on each boiler’s Sage2.1™ Control and will target a setpoint 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 generated to the Tekmar 264,

the control will de-energize the zone pump control (ZC terminal), energize the Indirect pump and sequentially re the boilers to establish a setpoint temperature in the main

for the Indirect Heater using Priority. The Tekmar 264 Control will disable the stage ring and post purge the Indirect Pump to reduce the temperature in the Supply Main

near the end of the Indirect Mode to a point where it will need to be when it changes back to Space Heating Mode. The Tekmar 264 Control also has the ability to rotate the

lead-lag ring of the boilers to establish equal operating time for each boiler stage.

Page 81

VIII. Electrical (continued)

G. Multiple Boiler Operating Information

1. Required Equipment and Setup

a. Header Sensor (p/n 103104-01)

A header sensor must be installed and wired

to the Master Sequencer “enabled” Sage2.1 Controller. The header sensor is installed on the common system piping and provides blended temperature information to the Sequence Master. Refer to piping diagram Figures 40A and 41A for installation location and Figure 48 or 49 for installation detail.

b. RJ45 Splitters (P/N 103192-01)

RJ45 Splitters are required for installing

communications between three or more boilers. When two boilers are connected the splitter is not required.

c. Ethernet Cables

Ethernet cables are used to connect the boiler

network together. These are standard “straight through” cables that can be purchased at electrical distributors.

Alternately, the network can be wired together

by simply wiring terminal J3, Modbus 2, terminals A, B and V- between each boiler. Refer to Figures 43 and 44 terminal J3 for wiring location.

Figure 48: Recommended “Immersion”

Type Header Sensor Installation Detail

Note: The “Strap-On” type sensor must be mounted to the top side of a horizontal section of pipe as indicated in Figures 40A and 41A.

Figure 49: Alternate “Strap-On” Type Header

Sensor Installation Detail

103448-02 - 6/13 81

Page 82

VIII. Electrical (continued)

Figure 50: RJ45 Splitter Installation Detail

d. Multiple Boiler Setup

Step Description Comments

Wire the header sensor to low voltage terminal strip terminals “Header sensor”.

Install and wire the Header

Sensor

Install Ethernet Cables

between boilers

3 Apply Power to All Boilers

Set Unique Boiler

Addresses

5 Enable 1 Boiler Master

6 Power Down All Boilers

Power Up Master

Sequencer “Enabled” Boiler First

This step can not be skipped. The Sequence Master can not be “enabled”unless a Header

Sensor is installed.

Standard Ethernet type cables with RJ45 connectors are “plugged in” to the Boiler-to-Boiler Communication Network connection located on the side of the boiler. When more than two boilers are connected an RJ45 splitter may be used to connect the boilers. Refer to Figure

50.

Assign all boilers a unique Boiler Address using any number from 1 through 8.

When two boiler’s addresses are the same undesirable simultaneous operation occurs.

Enable only one Control’s Sequencer Master.

When more than one Sequencer Master is enable erratic behavior will result.

NOTE

WARNING

8 Power Up Other Boilers

From the Home Screen of the Control with the Master Sequencer “enabled”, select the Status button. The Sequencer display shows the boiler address of the communicating boilers.

9 Conrm Communication

Additionally, from the “Home” screen select the “Detail” button and then the “Networked Boilers” buttons to view boiler communication status.

If a boiler is not shown, check Ethernet cable connections and conrm all boilers have unique

addresses.

82 103448-02 - 6/13

Page 83

IX. System Start-up

A. Verify that the venting, water piping, gas piping and

electrical system are installed properly. Verify that the

boiler condensate trap is lled with water. Refer to

installation instructions contained in this manual.

B. Conrm all electrical, water and gas supplies are turned

off at the source and that vent is clear of obstructions.

C. Conrm that all manual shut-off gas valves between

the boiler and gas source are closed.

WARNING

Completely read, understand and follow all instructions in this manual before attempting start up.

D. If not already done, ush the system to remove

sediment, ux and traces of boiler additives. This must

be done with the boiler isolated from the system. Fill entire heating system with water meeting the following requirements:

NOTICE

pH between 7.5 and 9.5. If system contains aluminum components, pH

must be less than 8.5 Total Dissolved Solids - less than 2500 PPM Hardness - 3 to 9 grains/gallon.

Pressurize the system to at least 12 PSI. Purge air from

the system.

2. Alpine gas valves have inlet and outlet pressure taps with built-in shut off screw. Turn each screw from fully closed position three to four turns counterclockwise to open taps. Connect manometers to pressure taps on gas valve.

NOTICE

If it is required to perform a long term pressure test of the hydronic system, the boiler should

rst be isolated to avoid a pressure loss due to

the escape of air trapped in the boiler. To perform a long term pressure test including

the boiler, ALL trapped air must rst be removed

from the boiler. A loss of pressure during such a test, with no

visible water leakage, is an indication that the boiler contained trapped air.

3. Temporarily turn off all other gas-red appliances.

4. Turn on gas supply to the boiler gas piping.

5. Open the eld installed manual gas shut-off valve

located upstream of the gas valve on the boiler.

6. Conrm that the supply pressure to the gas valve is 14 in. w.c. or less. Refer to Table 24 for minimum

supply pressure.

7. Using soap solution, or similar non-combustible solution, electronic leak detector or other approved method. Check that boiler gas piping valves, and all other components are leak free. Eliminate any leaks.

WARNING

The maximum operating pressure of this boiler is 30 psig, 50 psig, 80 psig or 100 psig depending on the model and relief valve option selected. Never exceed these pressures. Do not plug or change safety relief valve.

E. Conrm that the boiler and system have no water

leaks.

Do not use matches, candles, open ames or

other ignition source to check for leaks.

8. Purge gas line of air.

G. Operating Instructions

Start the boiler using the lighting instructions, see

Figure 51. After the boiler is powered up, it should go

through the following sequence. Refer to Section X,

“Operation” to locate and view sequence status.

DANGER

F. Prepare to check operation.

1. Obtain gas heating value (in Btu per cubic foot) from gas supplier.

103448-02 - 6/13 83

Page 84

IX. System Start-up (continued)

Alpine™ Series Lighting and Operating Instructions

84 103448-02 - 6/13

Figure 51: Lighting Instructions

Page 85

IX. System Start-up (continued)

Status Control Action

Initiate Power-up

This state is entered when a delay is

Standby Delay

Standby

Safe Startup

Drive Purge

Prepurge

Drive Light-off

Pre-ignition

Test

Pre-ignition

Direct

Ignition

Running

Postpurge

Lockout

needed before allowing the burner control to be available and for sensor errors.

Boiler is not ring. There is no call for

heat or there is a call for heat and the temperature is greater than setpoint.

Tests ame circuit then checks for ame

signal.

Driving blower to purge rate setting and

waiting for the proper fan feedback.

Purges the combustion chamber for the 10 second purge time.

Driving blower to light-off rate setting and

waiting for the proper fan feedback.

Tests the safety relay and veries that

downstream contacts are off.

Energizes the igniter and checks for ame.

Opens main fuel valve and attempts to ignite the main fuel directly from the ignition source.

Normal boiler operation. Modulation rate depends on temperature and setpoint selections and modulating control action.

Purges the combustion chamber for the 30 second purge time.

Prevents system from running due to a detected problem and records fault in

Lockout History.

H. Purge Air From Gas Train

Upon initial start-up, the gas train will be lled with air.

Even if the gas line has been completely purged of air,

it may take several tries for ignition before a ame is

established. If more than 5 tries for ignition are needed, it will be necessary to press the reset button to restart

the boiler. Once a ame has been established for the rst time, subsequent calls for burner operation should result in a ame on the rst try.

I. Check Burner Flame

Inspect the ame visible through the window. On high

re the ame should be stable and mostly blue (Figure

52). No yellow tipping should be present; however,

intermittent ecks of yellow and orange in the ame are

normal.

J. Check Gas Inlet Pressure

Check the inlet pressure and adjust if necessary. Verify

that the inlet pressure is between the upper and lower limits shown on the rating plate with all gas appliances on and off.

WARNING

The outlet pressure for the gas valve has been

factory set and requires no eld adjustment. This

setting is satisfactory for both natural gas and

propane. Attempting to adjust the outlet pressure

may result in damage to the gas valve and cause

property damage, personal injury or loss of life.

K. For LP Gas, perform procedure as described in

Paragraph R “Field Conversion From Natural Gas to LP Gas” before starting Paragraph L “Checking/Adjusting Gas Input Rate”.

For natural gas, proceed to Paragraph L “Checking/

Adjusting Gas Input Rate”.

L. Checking / Adjusting Gas Input Rate

1. Turn off gas supply to all appliances other than gas-

red boiler.

2. Light main burner by adjusting thermostat to highest

setting.

3. Clock gas meter for at least two (2) revolutions of the dial typically labeled ½ or 1 cubic foot per revolution on a typical gas meter.

4. Determine gas ow rate in Cubic Feet per Hour

based on elapsed time for two revolutions.

Example: Using a meter with dial labeled 1 cubic foot per

revolution, measured time is 72 Seconds for (2)

Revolutions, i.e. 36 seconds per 1 cubic foot.

Calculate hourly gas ow rate: 3600 sec/hr ÷ 36 sec/cu ft = 100 cu ft/hr

103448-02 - 6/13 85

Figure 52: Burner Flame

Page 86

IX. System Start-up (continued)

5. Obtain gas-heating value (Btu per cubic foot) from gas supplier.

6. Multiply hourly gas ow rate by gas heating value

to determine the boiler input rate, BTU/hr

Example:

Natural gas heating value provided by local gas

utility is 1050 Btu per cubic foot.

Measured and calculated hourly gas ow rate is 100

cu ft/hr.

Measured boiler input rate is: 100 cu ft/hr x 1050 BTU/ cu ft = 105, 000 BTU/hr

7. Compare measured input rate to input rate value stated on rating label. Strive to adjust the boiler input rate within 88% to 100% of the value listed on the boiler rating label.

8. If measured input is too high, reduce input rate by rotating gas valve throttle screw clockwise (see Figure 53) in ¼ turn increments and checking the rate after every adjustment until the measured input rate value falls within 88% to 100% of the value listed on the boiler rating label.

9. If measured input is too low, increase input rate by rotating gas valve throttle screw counterclockwise (see Figure 53) in ¼ turn increments and checking the rate after every adjustment until the measured input rate value falls within 88% to 100% of the value listed on the boiler rating label.

10. Once the boiler input rate adjusted/conrmed, recheck main burner ame and perform combustion

test as described below (see Paragraph M “ Perform Combustion Test”).

11. Upon completion, return other gas-red appliances

to previous condition of use.

M. Perform Combustion Test

Boilers are equipped with Flue Temperature Sensor

installed into:

• Flue sensor port of boiler CPVC/PVC two-pipe

vent system connector (oor standing build) -

See Figures 6 and 17.

• Flue sensor port of vent elbow, located inside air

box behind access panel (wall hung build) - see Figure 7B.

• Flue sensor port of boiler concentric vent collar

(oor standing build) - see Figure 18.

Remove Flue Temperature Sensor and insert the

analyzer probe through Flue Temperature Sensor silicon cap opening, or if required, remove also the Flue Temperature Sensor silicon cap and insert the analyzer

probe directly into ue sensor port. Reinstall the sensor

and the cap upon combustion testing completion.

Check CO

(or O2) and CO at both high and low re.

The boiler may be locked into high or low re as

follows:

1. To lock the boiler in high re, enter the Manual Control screen by rst entering the Adjust screen.

To access the Adjust screen, touch the Adjust button, then Login using the contractor password “076”. Press Save and then select the adjust button. Enter the Manual Control button and select “High”. Allow the boiler to operate for approximately 5 minutes before taking combustion readings.

2. To lock the boiler in low re select “Low” from

the Manual Control screen. Allow the boiler to operate for approximately 5 minutes before taking combustion readings.

3. Normal modulation of the boiler will only occur after the “Auto” button is selected in the Manual Control screen.

Typical CO2 values for natural gas are shown in Table

26.

Typical CO

values for LP gas are shown in Table 27.

If actual combustion readings are outside of typical

values shown, contact factory for assistance.

WARNING

Each Alpine Series boiler is tested at the factory and adjustments to the air fuel mixture are normally not necessary. Improper gas valve or mixture adjustments could result in property damage, personal injury, or loss of life.

Table 26: Typical Combustion Values, Natural Gas

Boiler

Model

ALP080B

ALP105B

ALP150B

ALP210B

ALP285B

ALP399

% CO

9.9 - 8.2

(High Fire)

9.9 - 7.9

(Low Fire)

Altitude Range

0 - 7000 Ft.

% O2 Range CO, PPM

3.5 - 6.5

(High Fire)

3.5 - 7.0

(Low Fire)

Less than 100 PPM

86 103448-02 - 6/13

Page 87

IX. System Start-up (continued)

Table 27: Typical Combustion Values, LP Gas

Boiler

Model

ALP080B ALP105B ALP150B ALP210B ALP285B

ALP399

% CO

11.4 - 9.5

(High Fire)

11.4 - 9.1

(Low Fire)

Altitude Range

0 - 7000 Ft.

% O2 Range CO, PPM

3.5 - 6.5

(High Fire)

3.5 - 7.0

(Low Fire)

Less than

100 PPM

WARNING

These instructions include a procedure for adjusting the air-fuel mixture on this boiler.

This procedure requires a combustion analyzer

to measure the CO2 (or Oxygen) and Carbon

Monoxide (CO) levels in ue gas. Adjusting the

air-fuel mixture without a proper combustion analyzer could result in unreliable boiler operation, personal injury, or death due to carbon monoxide poisoning.

4. While the burner is at high re adjust the throttle

as needed to obtain the CO

(or O2) settings shown

in the Table 26 (for natural gas) or Table 27 (for LP gas):

• To reduce the CO2 (increase the O2) turn the

throttle clockwise

• To increase the CO2 (reduce the O2) turn the

throttle counter-clockwise

Make adjustments in increments of 1/8 to 1/4 turn

and allow the boiler at least a minute to respond to each adjustment before making another. In general, the CO level will be at its lowest somewhere in the CO2 range shown in this table.

5. Verify that the gas inlet pressure is between the upper and lower limits shown in Table 24 with all gas appliances (including the converted boiler) both on and off.

6. To lock the boiler in low re, select “Low” from

manual control screen. If measured % O2 on LF, is out of spec (see Table 26 or 27), then turn offset screw clockwise (see Figure 53) to lower % O2 or vice versa.

WARNING

Offset screw on each Alpine Series boiler is

adjusted at the factory to the specication. DO

NOT touch the offset screw if measured 02 on Low Fire is in the spec (see Table 26 or 27).

7. If the boiler is converted from natural to LP gas then use a label sheet which is provided with the boiler for conversions from natural to LP gas. Otherwise skip this Step and proceed to Step 8. Once conversion is completed, apply labels as follows:

• Apply the “Rating Plate Label” adjacent to the

rating plate.

• Apply the “Gas Valve Label” to a conspicuous

area on the gas valve.

• Apply the “Boiler Conversion Label” to a

conspicuous surface on, or adjacent to, the outer boiler jacket. Fill in the date of the conversion and the name and address of the company making the conversion with a permanent marker.

8. Install Flue Temperature Sensor into:

• Flue sensor port of boiler CPVC/PVC two-pipe

vent system connector (oor standing build) -

See Figures 6 and 17.

• Flue sensor port of vent elbow, located inside air

box behind access panel (wall hung build) - see Figure 7B.

• Flue sensor port of boiler concentric vent collar

(oor standing build) - see Figure 18.

9. Install Access Panel/Gasket Assembly as shown in Figure 2E.

WARNING

Access Panel must be installed after the vent pipe is fully secured into the vent elbow. Failure to properly secure the vent into the elbow with clamp, could lead to property damage, personal injury or loss of life.

N. Test External Limits

Test any external limits or other controls in accordance

with the manufacturer’s instructions.

O. Check Thermostat Operation

Verify that the boiler starts and stops in response to

calls for heat from the heating thermostat and indirect water heater thermostat. Make sure that the appropriate circulators also start and stop in response to the thermostats.

P. Adjust Supply Water Temperature

As shipped, the heating set point supply temperature is

set to 180°F and, indirect water heater set point supply temperature is set to 170°F. If necessary, adjust these to the appropriate settings for the type of system to which this boiler is connected. See Section X “Operation” (parameter Table on page 107) of this manual for information on how to do this.

103448-02 - 6/13 87

Page 88

IX. System Start-up (continued)

Q. Adjust Thermostats

Adjust the heating and indirect water heater thermostats

to their nal set points.

R. Field Conversion From Natural Gas to LP Gas

Alpine Series boilers are factory shipped as Natural Gas

builds. Follow steps below for eld conversion from

Natural Gas to LP Gas.

WARNING

This conversion should be performed by a

qualied service agency in accordance with the

manufacturer’s instructions and all applicable

codes and requirements of the authority

having jurisdiction. If the information in these

instructions is not followed exactly, a re, an

explosion or production of carbon monoxide may result causing property damage, personal injury,

or loss of life. The qualied service agency is

responsible for proper conversion of these boilers. The conversion is not proper and complete until the operation of the converted boiler is checked

as specied in this manual.

Table 28: Number of Clockwise Throttle Screw

Turns for LP Conversion

Throttle Screw Turns at

Boiler Model Gas Valve

ALP080B

ALP105B 4

ALP150B 3¼

ALP210B 4

ALP285B

ALP399

Dungs

GB-055

(½” NPT)

Dungs

GB-057

(¾” NPT)

Dungs

GB-057 HO

(¾” NPT)

Altitude Range

0 - 7000 Ft.

2¾

4½

1¾

1. All Alpine boiler models can be converted from Natural Gas to LP Gas.

2. Conversion of Alpine Series boilers from one fuel to another is accomplished using the throttle screw on the gas valve. Figure 53 shows the location of the throttle screw on the Dungs valve. Locate the throttle on the boiler being converted.

3. If conversion is being made on a new installation, install the boiler in accordance with the installation instructions supplied with the boiler. If an installed boiler is being converted, connect the new gas supply to the boiler, check for gas leaks, and purge the gas line up to the boiler in accordance with the National Fuel Gas Code (ANSI Z223.1) or the requirements of the authority having jurisdiction.

4. Before attempting to start the boiler, make the number of turns to the throttle screw called for in Table 28.

5. Attempt to start the boiler using the lighting instructions located inside the lower front cover of

the boiler. If the boiler does not light on the rst

try for ignition, allow to boiler to make at least four more attempts to light. If boiler still does not light, turn the throttle counter clockwise in 1/4 turn increments, allowing the boiler to make at least three tries for ignition at each setting, until the boiler lights.

Figure 53: Dungs Gas Valve Detail

6. Go back to Paragraph L “Checking/Adjusting Gas Input Rate” and Paragraph M “Perform Combustion Test”.

88 103448-02 - 6/13

Page 89

IX. System Start-up (continued)

WARNING

The throttle adjustments shown in Table 28 are approximate. The nal throttle setting must be found using

a combustion analyzer. Leaving the boiler in operation with a CO level in excess of the value shown in Table 27 could result in injury or death from carbon monoxide poisoning.

NOTICE

If the throttle is very far out of adjustment on the “rich” (counter-clockwise) side, the boiler burner may be

running at 0% Excess Air or even with air deciency.

At 0% Excess Air the CO2 readings will be either 11.9% CO2 for Natural Gas or 13.8% CO2 for LP Gas (O2 will be 0%) and CO level will be extremely high (well over 1000 PPM).

If the burner operates with air deciency, the following phenomena may be observed:

% CO2 will actually drop (% O2 will increase) as the throttle is turned counterclockwise

% CO2 will actually increase (% O2 will drop) as the throttle is turned clockwise

If the boiler appears to operate with air deciency, turn the throttle clockwise to increase the amount of

Excess Air to the burner.

As the throttle is turned clockwise, the CO2 level will rise, eventually peaking @ 11.8% or 13.8%, depending of the type of gas being used, before falling (conversely, O2 level will drop to 0% before rising). After this happens, continue turning the throttle clockwise, until CO2 level drops (or O2 level increases) to the values shown in Table 26 or Table 27.

WARNING

The pressure regulator (offset screw) has been factory set using precision instruments and must never

be adjusted in the eld unnecessarily. The gas valve outlet pressure is the same for both natural gas and

propane. Make sure that all adjustments are made with the throttle, not the pressure regulator. Attempting to adjust the pressure regulator unnecessarily, may cause property damage, personal injury or loss of life.

103448-02 - 6/13 89

Page 90

IX. System Start-up (continued)

S. Controls Startup Check List

The Control is factory programmed with default parameters. Before operating the boiler, these parameters must be checked

and adjusted as necessary to conform to the site requirements. Follow the steps below, making selections and adjustments as necessary to ensure optimal boiler operation.

No. Title Terminal Description

1 & 2

2 & 3 Is an Indirect Water Heater (IWH) providing a boiler heat demand?

5 & 6

From the Home Screen press the Adjust button and login to access the adjust mode screens (if required, refer to X. Operation Section, “Entering Adjustment Mode” Paragraph G, 1 for login instructions). The following parameters should be reviewed:

No. Menu Parameter Description

8 DHW

10 Sequencer Master Slave

Check

Wiring

System

Setup

Modulation

Setup

Pump Setup

Contractor

Setup

Manual Control

Central

Heat

Remote 4-20mA

7 & 8 Is a header sensor used? If yes, refer to step 10 below to activate this feature.

9 & 10

11 & 12 Is an External Limit used? Remember to remove factory-installed jumper.

LWCO Plug Is a LWCO required? Check installation of the LWCO.

Warm Weather

Shutdown

Warm Weather

Shutdown Setpoint

Boiler Type

System Pump

Boiler Pump

Domestic Pump

Contractor Name

Address

Phone

Manual Speed

Control

Setpoint Ensure Setpoint, (ring rate target temperature) is correct for you type of radiation.

Setback

Setpoint

Setpoint Ensure Setpoint, (ring rate target temperature) is suitable for the IWH requirements.

Setback

Setpoint

Modulation Source

Setpoint Source Set to 4-20mA when a Energy Management system is sending a “remote” setpoint.

Is the heating thermostat connected? Insure this is “dry”, non-powered input.

Is an Outdoor Air sensor used? If no, select outdoor sensor type “not installed” under

system menu.

Is a Remote 4-20mA required for a Energy Management System or external multiple boiler control? If used see step 9 below to activate this input.

Selecting “Enable” will restrict boiler start during warm weather (only if an outdoor air temperature sensor is installed).

Use this setting to adjust the temperature that the WWSD function will shut boiler off.

WARNING

Conrm that the correct boiler model is shown. Stop installation and contact factory if the wrong boiler model is shown.

Ensure that the pump parameter selections are correct for your heating system. Refer

to Paragraph G. Adjusting Parameters, Pump Setup Menu for additional information.

Enter your contact information, name, address, and phone number on this screen.

In the event of a fault or the need to adjust a setting the display will direct the homeowner to you.

Use the “High and “Low” options to force the boiler to high re and low re for combustion testing.

Check the setting for the central heat setpoint when the T-Stat “Sleep” or “Away” Setback mode is entered (if EnviraCOM Setback thermostat is used).

Check the setting for the DHW setpoint when the T-Stat “Sleep” or “Away” Setback mode is entered (if EnviraCOM Setback thermostat is used).

Set to 4-20mA when an external multiple boiler controller is connected to the system.

Refer to Sequencer Master Setup Section X, G if multiple boilers are installed at this

site.

90 103448-02 - 6/13

Page 91

X. Operation (A. Overview)

180 F

Boiler 1

Energy Save On Max Efficiency On

Standby

Status

Help

Adjust

Detail

A. Overview

1. Sage 2.1 Controller The Sage 2.1 Controller (Control) contains features and

capabilities which help improve heating system operation, efficiency and home comfort. By including unique

capabilities, the Control can do more, with less eld

wiring, and fewer aftermarket controls and components – improving the operation of both new and replacement boiler installations.

2. Advanced Touch Screen Display

Home Screen

Boiler status and setup selections are available from an

easy to use, dual color, LCD Touch Screen Display. Over one hundred helpful information screens are provide to explain status information and setup functions. In the event of a fault condition the user is guided by “blinking” touch buttons to Help screens that explain the problem cause and corrective action. Operation evaluation and problem-solving is enhanced by historical capability including graphic trends, lockout history records as well as boiler and circulator cycle counts and run time hours.

3. Advanced Modulating Control The Control modulates the boiler input by varying the fan

speed. As the fan speed increases, so does the amount of fuel gas drawn into the blower. As a result, a fairly constant air-fuel ratio is maintained across all inputs. The Control determines the input needed by looking at both current and recent differences between the measured temperature and the setpoint temperature. As the measured temperature approaches the setpoint temperature, the fan will slow down and the input will drop. The Control also utilizes boiler

return water and ue gas temperatures to adjust fan speed.

4. Built-in Safety Control The Control includes safety controls designed to ensure safe

and reliable operation. In addition to ame safety controls

the Control includes supply water temperature, differential water temperature, and stack temperature safety limits and stepped modulation responses. Boiler modulation is adjusted when required to help avoid loss of boiler operation due to exceeding limits. Additionally, the Control accepts the

optional eld installation of low water cut-off and auxiliary

safety limits.

5. Outdoor Air Reset When selected the modulation rate setpoint is automatically

adjusted based on outside air temperature, time of day and length of demand (boost) settings. Outdoor air “reset” setpoint saves fuel by adjusting the water temperature of a

103448-02 - 6/13 91

heating boiler lower as the outside air temperature increases.

6. Warm Weather Shutdown (WWSD) Some boilers are used primarily for heating buildings,

and the boilers can be automatically shutdown when the outdoor air temperature is warm. When outside air temperature is above the WWSD setpoint, this function will shut down the boiler, boiler pump and/or the system pump.

7. Domestic Hot Water Priority (DHWP) Some boilers are used primarily for building space heating,

but also provide heat for the domestic hot water users. When the outdoor temperature is warm, the outdoor reset setpoint may drop lower than a desirable domestic hot water temperature. Also, often it is required to quickly recover the indirect water heater. When DHWP is enabled, heating circulators are stopped, the domestic circulator is started and the domestic hot water setpoint is established in response to a domestic hot water demand. Priority protection is provided to allow the heating loop to be serviced again in the event of an excessively long domestic hot water call for heat.

8. Energy Management System (EMS) Interface The control accepts a 4-20mAdc input from the EMS

system for either direct modulation rate or setpoint.

9. Circulator Control The Control may be used to sequence the domestic hot

water, boiler and system circulators. Service rated relay outputs are wired to a line voltage terminal block for easy

eld connection. Simple parameter selections allow all

three pumps to respond properly to various hydronic piping arrangements including either a boiler or primary piped indirect water heater. Circulators are automatically run for a 20 second exercise period after not being used for longer than 7 days. Circulator exercise helps prevent pump rotor seizing.

10. Multiple Boiler Sequencer Peer-To-Peer Network The Control includes state-of-the-art modulating lead-

lag sequencer for up to eight (8) boilers capable of auto rotation, outdoor reset and peer-to-peer communication. The peer-peer network is truly “plug and play”. Communication is activated by simply connecting a RJ45 ethernet cable between boilers. The Control provides precise boiler coordination by sequencing boilers based on both header water temperature and boiler modulation

rate. For example, the lead boiler can be congured to

start a lag boiler after operating at 50% modulation rate for longer than an adjustable time. The boilers are modulated in “unison” (parallel) modulation rate to ensure even heat distribution

11. Modbus Communication Interface

A factory congured RS485 Modbus interface is available

for Energy Management System (EMS)monitoring when not used for Multiple Boiler Sequencer Peer-To-Peer Network. Consult factory if this interface must be used in addition to the boiler Peer-to-Peer Network.

Page 92

X. Operation B. Supply Water Temperature Regulation (continued)

B. Supply Water Temperature Regulation

1. Priority Demand

The Control accepts a call for heat (demand) from

multiple places and responds according to it’s “Priority”. When more than 1 demand is present the higher priority demand is used to determine active boiler settings. For example, when Domestic Hot Water (DHW) has priority the setpoint, “Diff Above”, “Diff Below” and pump settings are taken from DHW selections. Active “Priority” is displayed on the “Boiler Status” screen.

Table 29: Priority

Status

Priority

1st Sequencer

2nd Domestic Hot

3rd Central Heat Central Heat call for heat is on and

4th Frost

5th Warm

6th Standby There is no demand detected.

2. Setpoint Purpose The Control starts and stops the boiler and modulates

3. Central Heat Setpoint Upon a Central Heat call for heat the setpoint is either

Screen

Display

Control

Water

Protection

Weather

Shutdown

(WWSD)

Boiler Responding to:

The boiler is connected to the peerto-peer network. The boiler accepts demand from the Sequencer Master.

DHW call for heat is on and selected as the priority demand. DHW is always higher priority than Central

Heat. It also has higher priority than

the Sequencer Control when DHW priority is “enabled” and “Boiler Piped” IWH is selected.

there is no DHW demand or DHW priority time has expired.

Frost Protection is active and there is no other call for heat. Frost protection will be a higher priority than Sequencer Control if the Sequence Master has no active call for heat.

WWSD is active and the boiler will not respond to central heat demands. DHW demand is not blocked by WWSD.

the boiler input from minimum (MBH) to maximum (MBH) in order to heat water up to the active setpoint. The setpoint is determined by the priority (Central Heat or Domestic Hot Water) and as described in the following paragraphs.

the user entered Central Heat Setpoint or is automatically adjusted by a thermostat’s “Sleep” or “Away” modes and/ or Outdoor Air Reset or a Energy Management System (EMS) supplied 4-20mAdc setpoint.

4. Outdoor Air Reset If an outdoor temperature sensor is connected to the boiler

and Outdoor Reset is enabled, the Central Heat setpoint will automatically adjust downwards as the outdoor temperature increases. When the water temperature is properly matched to home heating needs there is minimal chance of room air temperature overshoot. Excessive heat is not sent to the room heating elements by “overheated” (supply water temperature maintained too high a setting) water. Reset control saves energy by reducing room over heating, reducing boiler temperature & increasing

combustion efciency and reducing standby losses as a

boiler and system piping cool down to ambient following room over heating.

5. Boost Time When the Central Heat Setpoint is decreased by Outdoor

Air Reset settings the Boost function can be enabled to increase the setpoint in the event that central heat demand

is not satised for longer than the Boost Time minutes.

The Boost feature increases the operating temperature

setpoint by 10°F every 20 minutes (eld adjustable) the central heat demand is not satised. This process will continue until heat demand is satised (indoor air is at desired temperature). Once the heat demand is satised,

the operating setpoint reverts to the value determined by the Outdoor Air Reset settings. If Boost Time is zero, then the boost function is not used.

6. Domestic Hot Water (DHW) Setpoint Upon a DHW call for heat the setpoint is either the user

entered DHW setpoint or the Thermostat’s “Sleep” or “Away” DHW setpoint. The optimal value of this setpoint is established based on the requirements of the indirect water heater.

7. Domestic Hot Water Priority (DHWP) When domestic hot water priority is selected and there

is a DHW call for heat, the system pump will be turned off (when system pump parameter is set for “Central Heat Optional Priority”) and the DHW pump will be turned on. Additionally, if outdoor reset is active, the active setpoint is adjusted to the DHW Setpoint. Priority protection is provided to ensure central heat supply in the case of excessively long DHW call for heat.

8. “Setback” Setpoints User adjustable Thermostat “Sleep” or “Away” Setback

Setpoints are provided for both Central Heat and DHW demands. The Setback setpoint is used when the EnviraCOM thermostat is in “leave” or “sleep” modes. When setback is “on” the thermostat setback setpoint shifts the reset curve to save energy while the home is in reduced room temperature mode. The Honeywell VisionPro IAQ (part number TH9421C1004) is a “setback” EnviraCOM enabled thermostat.

92 103448-02 - 6/13

Page 93

X. Operation C. Boiler Protection Features (continued)

C. Boiler Protection Features

1. Supply Water Temperature High Limit The boiler is equipped with independent automatic reset

and a manual reset High Limit devices. The automatic reset high limit is provided by a supply manifold mounted Limit Device. The automatic high limit is set to 200°F. The Control monitors a supply water temperature sensor that is also mounted in the supply water manifold and supplies an internal, manual reset high limit. If supply water temperature exceeds 190°F, the control begins to reduce the blower maximum speed setting. If the temperature exceeds 200°F, a forced recycle results. If the temperature exceeds 210°F, a manual reset hard lockout results. Additionally, if the supply temperature rises faster than the degrees Fahrenheit per second limit a soft lockout is activated.

2. High Differential Temperature Limit The Control monitors the temperature difference between

the return and supply sensors. If this difference exceeds 43°F the control begins to reduce the maximum blower speed. If temperature difference exceeds 53°F a forced boiler recycle results. If the temperature difference exceeds 63°F the control will shut the unit down. The unit will restart automatically once the temperature difference has decreased and the minimum off time has expired.

3. Low Water Cut Off (LWCO) The Control shuts down the boiler when either the

supply water temperature is too high or supply to return temperature differential temperature is too high. This ensures the boiler is shutdown in the event of a low water

level or low water ow condition.

Some codes and jurisdiction may accept these integral

features instead of requiring a low water cutoff. ADHERE TO ALL LOCAL CODE REQUIREMENTS. Contact your local code inspector prior to installation. If required, a LWCO four-position wire harness connection is provided for an external LWCO kit (p/n 102097-01) to be added. If the LWCO opens, the boiler will shut down and an open limit indication and error code is provided. If the limit installed is a manual reset type, it will need to be reset before the boiler will operate.

4. Return Temperature Higher Than Supply Temperature

(Inversion Limit)

The Control monitors the supply and return temperature

sensors. If the return water temperature exceeds the supply water temperature for longer than a limit time delay the Control shuts down the boiler and delays restart. If the inverted temperature is detected more than

ve times the boiler manual reset Hard Lockout is set.

This condition is the result of incorrectly attaching the supply and return piping.

5. External Limit An external limit control can be installed between

terminals 11 and 12 on the low voltage terminal strip. Be sure to remove the jumper when adding an external limit control to the system. If the external limit opens, the boiler will shut down and an open limit indication and error code is provided. If the limit installed is a manual reset type, it will need to be reset before the boiler will operate.

6. Boiler Mounted Limit Devices The Control monitors individual limit devices: pressure

switch, high limit device, condensate level switch, Thermal Link (ALP285 and ALP399), Burner Door Thermostat with manual reset (ALP285 and ALP399), low water cutoff (optional), fuel gas pressure switches (optional) and external limit (optional). If any of these limits opens, the boiler will shut down and an individual open limit indication is provided.

7. Stack High Limit

The Control monitors the ue gas temperature sensor

located in the vent connector. If the ue temperature

exceeds 184°F, the control begins to reduce the maximum

blower speed. If the ue temperature exceeds 194°F, a forced boiler recycle results. If the ue temperature

exceeds 204°F, the control activates a manual reset Hard Lockout.

8. Ignition Failure The Control monitors ignition using a burner mounted

ame sensor. In the event of an ignition failure, the

control retries (ALP080B through ALP399) 5 times and then goes into soft lockout for one hour.

9. Central Heating System Frost Protection When enabled, Frost Protection starts the boiler and

system pump and res the boiler when low outside air

and low supply water temperatures are sensed. The Control provides the following control action when frost protection is enabled:

Table 30: Frost Protection

Device

Started

Boiler &

System Pump

Boiler Supply Water < 38°F Supply Water > 50°F

Supply Water < 45°F

Start

Temperatures

Outside Air < 0°F

Stop

Temperatures

Outside Air > 4°F

Supply Water > 50°F

FROST PROTECTION NOTE

The Control helps provide freeze protection for the boiler

water. Boiler ue gas condensate drain is not protected from

freezing. Since the Control only controls the system and boiler circulators individual zones are not protected. It is recommended that the boiler be installed in a location that is not exposed to freezing temperatures.

103448-02 - 6/13 93

Page 94

X. Operation D. Multiple Boiler Control Sequencer (continued)

D. Multiple Boiler Control Sequencer

1. “Plug & Play” Multiple Boiler Control Sequencer When multiple boilers are installed, the Control’s

Sequencer may be used to coordinate and optimize the operation of up to eight (8) boilers. Boilers are connected into a “network” by simply “plugging in” standard ethernet cables into each boiler’s “Boiler-To-Boiler Communication” RJ45 connection.

2. Sequencer Master A single Control is parameter selected to be the Sequencer

Master. The call for heat, outdoor and header sensors, and common pumps are wired to the Sequencer Master “enabled” Control.

3. Lead/Lag Sequencing & Equalized Run Time One boiler is a “Lead” boiler . When demand is increasing,

the Lead boiler is the rst to start and the remaining

boilers are started in sequential order (1,2,3,…) until

the demand is satised. When demand is decreasing,

the boilers are stopped in reverse order with the Lead boiler stopped last (…,3,2,1). To equalize the run time the sequencer automatically rotates the Lead boiler after 24 hours of run time.

4. Improved Availability The following features help improve the heat availability:

a. Backup Header Sensor: In the event of a header sensor

failure the lead boiler’s supply sensor is used by the

Sequence Master to control ring rate. This feature

allows continued coordinated sequencer control even after a header sensor failure.

b. “Stand Alone” Operation Upon Sequence Master

Failure: If the Sequence Master Control is powered down or disabled or if communication is lost between boilers, individual boilers may be setup to automatically resume control as a “stand alone” boiler.

c. Boiler Rate Adjustment: Each boiler continues to

monitor supply, return and ue gas temperatures and modies the Sequence Master’s ring rate demand to

help avoid individual boiler faults, minimize boiler

cycling and provide heat to the building efciently.

d. Boiler Status Monitoring: The Sequence Master

monitors boiler lockout status and automatically skip over disabled boilers when starting a new boiler.

5. Customized Sequences Normally, boilers are started and stopped in numerical

order. However, custom sequences may be established to optimize the heat delivery. For example, in order to minimize boiler cycling, a large boiler may be selected

to run rst during winter months and then selected to

run last for the remainder of the year.

6. Multiple Demands The Sequence Master responds to Central Heat, DHW

and frost protection demands similar to the stand alone boiler. For example, when selected and DHW priority

is active, the sequence master uses DHW setpoint, “Diff Above”, “Diff Below” and pump settings.

7. Shared or Isolated DHW Demand When the Indirect Water Heater (IWH) parameter is set

to “Primary Piped” the Sequence Master sequences all required boilers to satisfy the DHW setpoint (default 180 F). When “Boiler Piped” is selected only the individual

boiler, with the wired DHW demand and pump, res 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” parameter is set to “Enabled” two boilers are started without delay in response to a DHW call for heat. This feature allows rapid recovery of large IWH’s and multiple IWH’s.

9. Optimized Boiler Modulation

Boiler ring rate is managed to increase smoothly as

boilers are started. For example, when a second boiler is

started the initial ring rate is 100%/2 or 50%, when the third boiler is started the ring rate starts at 200%/3 or

66%. After the initial start, the Sequence Master develops

a unison ring rate demand based on it’s setpoint and

sensed header temperature.

10. Innovative Condensing Boiler Control

During low loads, the Sequence Master limits ring rates

to a ‘Base Load Common Rate” to ensure peak operating

efciency. Lower ring rates boost efciency by helping increase the amount of ue gas water vapor condensation.

The Control maintains a “Base Load Common Rate” until the last lag boiler is started. At this point, the “Base Load Common Rate” is released to allow boilers to modulated as required to meet heat load.

11. Advanced Boiler Sequencing After there is a Call For Heat input, both header water

temperature and boiler ring rate percent are used to start

and stop the networked boilers. The control starts and stops boilers when the water temperature is outside the user selected “Diff Above” and “Diff Below” settings. Also, in order to minimize temperature deviations, the control adjusts the number of boilers running based on

the ring rate. This combination allows the boilers to

anticipate slow load changes before they disrupt water temperature yet still respond quickly to sudden load changes. These special sequencer features help reduce energy wasting system temperature swings and the resulting unnecessary boiler cycling.

12. Stop All Boilers All boilers are stopped without delay if the Call for Heat

input is removed or if the header temperature is higher

than 195°F (eld adjustable).

94 103448-02 - 6/13

Page 95

X. Operation E. Boiler Sequence Of Operation (continued)

E. Boiler Sequence of Operation

1. Normal Operation

Table 31: Boiler Sequence of Operation

Status Screen Display Description

Boiler 1

Supply

140 F

Setpoint

Rate

Priority:

Status:

140 F

Standby Standby

Priority:

Standby

Status:

Standby

(burner Off, circulator(s) Off)

Boiler is not ring and there is no call for heat, priority equals standby. The boiler is ready to respond to a call for heat.

Boiler 1

Supply

140 F

Setpoint

Rate

Priority:

Status:

Boiler 1

Supply

Setpoint

Rate

Priority:

Status:

140 F

Central Heat Standby

132 F 140 F

98%

Central Heat Prepurge 10

Priority:

Central Heat

Status:

Standby

Priority:

Central Heat

Status:

Prepurge

(burner Off, circulator(s) On)

Boiler is not ring. There is a Central Heat call for heat and the Supply temperature is greater than setpoint minus the “Diff Below”.

When supply temperature drops burner demand continues with following Status shown:

Safe Startup: Flame circuit is tested. Drive purge: The blower is driven to the fan purge speed. Prepurge: After the blower reaches the fan purge speed setting the 10 second combustion chamber purge is conducted.

Boiler 1

Supply

132 F

Setpoint

Rate

Priority:

Status:

Boiler 1

Supply

Setpoint

Rate

Priority:

Status:

Boiler 1

Supply

Setpoint

Rate

Priority:

Status:

140 F

89%

Central Heat Direct Ignition

132 F 140 F

100%

Central Heat Running

132 F 180 F

100%

Domestic Hot Water

Running

Priority:

Central Heat

Status:

Direct

ignition

Priority:

Central Heat

Status:

Running

Priority:

Domestic

Hot Water

Status:

Running

After purge time is complete the following Status is shown: Drive light-off: The blower is driven to light-off rate.

Pre-Ignition Test: After the blower reaches light-off rate a safety relay test is conducted. Pre-ignition: Spark is energized and it is conrmed that no ame is present Direct Ignition: Spark and Main fuel valve are energized.

(burner On, circulator(s) On)

After ame is proven normal boiler operation begins. Modulation rate depending on temperature and setpoint selections and modulating control action.

If the Central Heat call for heat is active and a Domestic Hot Water (DHW) call for heat received the DHW demand becomes the “priority” and the modulation rate, setpoint, “Diff Above” and “Diff Below” are based on DHW settings.

Priority:

Standby

Status:

Post-purge

Priority:

Standby

Status:

Standby

Delay

Priority:

Standby

Status:

Lockout

103448-02 - 6/13 95

(burner Off, circulator(s) Off)

If there is no call for heat the main fuel valve is closed and the blower is driven to the fan post-purge speed. After the blower reaches the fan post-purge speed setting the 30 second combustion chamber purge is conducted.

This state is entered when a delay is needed before allowing the burner control to be available. For example, when Anti-Short Cycle time is selected Standby delay is entered after the Central Heat call for heat ends. Select “Help” button from the “Home Screen” to determine the cause of the Standby Delay.

A lockout Status is entered to prevent the boiler from running due to a detected problem. Select “Help” button from the “Home Screen” to determine the cause of the Lockout. The last 10 Lockouts are recorded in the Lockout History.

Page 96

X. Operation E. Boiler Sequence Of Operation (continued)

2. Using The Display

The Control includes a touch screen LCD display. The user monitors and adjusts boiler operation by selecting screen

navigation “buttons” and symbols. The “Home Screen” and menu selections are shown below. When no selection is made, while viewing any screen, the display reverts to the “Home Screen” after 4 minutes. The “Home Screen” displays

boiler temperature, boiler status and Efciency Information. “Energy Save On” indication appears when the outdoor reset

or setback features have lowered the Central Heat Setpoint based on outside air temperature measurement or time of day.

“Max Efciency On” appears when the boiler return temperature has been reduced low enough to cause energy saving ue gas condensation.

Menu Button

Status

Detail

Help

Adjust

Boiler 1

180 F

Standby Energy Save On

Max Efficiency On

Home Screen

The Home Screen Menu Buttons connect the displays four main display groups; Status, Detail, Help and Adjustment Screens.

Close Symbol

The “Close” symbol returns to the display to previous menu or screen. Repeatedly pressing the “Close” symbol will always return the display to the “Home” screen.

i Active

Boiler 1

Supply

180 F

Setpoint

180 F

Rate

Priority:

Central Heat

Status: Standby

Fault

Status Screen

Arrow Symbol

The “Arrow” symbol links together all screens in the selected group. For example, repeated pressing the right “Arrow” symbol will rotate the display around all the screens in the Status group. Using this feature the user can review all the boiler status and adjustment mode screens.

Fault Symbols

“Active Fault” and “Rate Limit” symbols provide a link to the cause of a boiler fault or firing rate limit. The first boiler status screen provides an overview of boiler operation including fault status.

Information Symbol

“Information” symbol links most screens to screen content explanations. New terminology used in status and adjustment screens are explained in plain words.

Home Screen

Status

Detail

Help

Adjust

Boiler 1

180 F

Standby Energy Save On

Max Efficiency On

Boiler 1

Supply

Setpoint

180 F 180 F

Rate

Priority:

Status: Standby

Status Screens

(see Figure 54)

Central Heat

Domestic

Hot Water

96 103448-02 - 6/13

Outdoor

Reset Curve

Detail Menu

(see Figure 55)

Active Faults

Lockout

History

Service

Contract

Help Menu

(see Figure 60)

Sequencer

Setup

Boiler Size

Setup

Warning! Only Qualified Technicians

Should Adjust Controls, Contact Your

Qualified Heating Professional

Improper settings or service create risk of

property damage, injury, or death.

Service Contact Adjust

Adjust Mode Screens

(see Figure 56)

Page 97

X. Operation F. Viewing Boiler Status (continued)

F. Viewing Boiler Status

1. Status Screens Boiler Status screens are the primary boiler monitoring screens. The user may simply “walk” though boiler

operation by repeatedly selecting the right or left “arrow” symbol. These screens are accessed by selected the “Status” button from the “Home” screen.

Boiler 1

Supply

Setpoint

Domestic Hot Water Off

180 F 180 F

Rate

Priority:

Status: Standby

Heat Demand

Sequence Master Off

Frost Protection Off

Central Heat

Central Heat On

Supply:

measured supply water temperature. This is the temperature being used to start/stop and fire boiler when there is a call-for- heat.

Setpoint:

this is the active setpoint. This temperature is the result of Outdoor Air Reset, Setback and Domestic Hot Water (DHW) selections.

Rate:

The rate % value is equal to the actual fan speed divided by the maximum fan speed.

Priority:

The selected Priority is shown. Available Priorities are: Standby (no call for heat is present), Sequencer Control, Central Heat, Domestic HW, Frost Protection or Warm Weather Shutdown.

Pump Status/Cycles

Frost Protection On Exercise On

Status

Supply

180 F

Return

160 F

Stack

147 F

Rate

40 %

System On 98

Boiler On 23

DHW Off 0

Figure 54: Status Screens

i Active

Status:

Information found at the bottom of the Status screen and on the Home screen. Table 31 shows each status and the action the control takes during the condition.

Boiler 1

Supply

180 F

Setpoint

180 F

Rate

Priority:

Central Heat

Status: Standby

Fault

Trends

Flame

2.5 hour trend

Flame

5 minute trend

Boiler Cycles/Hours

Boiler Cycles

Run Time Hours

Supply / Return

Firing Rate

2000

800

Active fault:

A hard lockout will cause the active fault indication to appear. When visible the text becomes a screen link to the “Help” Menu.

Rate Limit:

The “

of the Rate % when firing rate is

” symbol appears to the right

limited or overridden in any way. During the start-up and shutdown sequence it is normal for the rate to be overridden by the purge and light-off requirements. When a rate limit is the result of boiler protection logic the “

” symbol blinks and becomes a

screen link

Trends

Flame

2.5 hour trend

Flame

5 minute trend

Supply / Return

Firing Rate

Data Logging Real time graphic trends allow users to observe process

changes over time providing valuable diagnostic information.

For example, ame current performance over start up

periods and varying loads can be an indication of gas supply issues. Additionally, supply and return temperature dual pen trends brings a focused look at heat exchanger and pump performance. For example, studying a differential temperature trend may indicate pump speed settings need to be changed.

103448-02 - 6/13 97

Boiler Cycles/Hours

Boiler Cycles

Run Time Hours

2000

800

Cycles and Hours

Boiler cycles and hours are used to monitor the boilers overall compatibility to the heating load. Excessive cycling compared to run time hours may be an indication of pumping, boiler sizing or adjustment issues.

Page 98

X. Operation F. Viewing Boiler Status (continued)

Central Heat

On Point - 7 F

Setpoint

Off Point +

5 F

Firing Rate 22% Setpoint: Outdoor Reset

180 F

Supply

Outdoor Reset

Outside Air

W a

180

130 110

0 70

Setpoint 164 F

Outside Air 16 F

Status: Enabled

1. Status Screens (continued)

Pump Status/Cycles

System On 98

Boiler On 23

DHW Off 0

Frost Protection On Exercise On

Pumping is a major part of any hydronic system. This screen provides the status of the boiler’s demand to connected pumps as well as the status of Frost Protection and pump Exercise functions.

2. Detail Screens

Detail screens are accessed by selected the “Detail”

button from the “Home” screen and provide in depth operating parameter status such as “On Point”, “Off Point” and Setpoint Source information.

Heat Demand

Central Heat On

Domestic Hot Water Off

Sequence Master Off

Frost Protection Off

This screen provides the status of the boiler’s 4 possible heat demands. When demand is off the Control has not detected the call-for-heat.

Demand detail screens are provided for Central Heat (shown), DHW and Sequencer demands.

98 103448-02 - 6/13

Outdoor Reset saves energy and improves home comfort by adjusting boiler water temperature . This screen presents the active reset curve. The curve shows the relationship between outside air and outdoor reset setpoint. The curve shown is adjustable by entering the display’s adjust mode.

Figure 55: Detail Screens

Page 99

X. Operation F. Viewing Boiler Status (continued)

3. Multiple Boiler Sequencer Screens

When the Sequence Master is enabled the following screens are available:

The Sequencer Status screen is selected by “pressing” “Status” button from the “Home” screen when Sequence Master is enabled.

Header:

measured header water temperature. This is the temperature being used to start, stop and fire boiler when there is a call-for-heat.

Setpoint:

this is the active setpoint. This temperature is the result of Outdoor Air Reset, Setback and Domestic Hot Water (DHW) selections.

Networked Boiler Status:

Provides connected, start sequence and firing rate status information for all connected boiler addresses. The boiler number is underlined if the boiler is running and blinks if the boiler has the start sequence in progress. For example the status for boiler address 1 is provided as follows: 1 - Boiler 1 is connected to the network 1 - “Blinking underline” - boiler 1 is starting 1 - “Solid underline” - boiler 1 is running

The “Networked Boilers” screen is selected by “pressing” the “Detail” button from the “Home” screens and “pressing” Networked Boilers” from the “Detail” screen.

Networked Boilers:

Sequencer

Header

Setpoint

Rate

Priority:

132 F 180 F

100%

Domestic Hot Water

1 ,2 ,3 ,4 ,5 ,6 ,7 ,8

Rate:

The rate % value is equal to the Sequence Master demand to the individual boiler. Actual boiler firing rate is found on the individual boiler status pages.

Priority:

The selected Sequencer Priority is shown. Available Priorities are: Standby (no call for heat is present), Central Heat, Domestic Hot Water, Frost Protection or Warm Weather Shutdown.

Boiler Number:

Up to eight (8) boiler’s status is shown

Lead Boiler:

Upon power up the lowest numbered boiler becomes the lead boiler. The lead boiler is the first to 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.

Networked Boilers

Boiler 1 Lead 50% Firing

Boiler 2 50% Firing

Boiler 3 0 % Available

Boiler 4 0 % Available

Sequence Status:

Slave boiler status is provide as follows:

Available:

Add Stage:

Running:

On Leave:

Recovering:

Disabled:

Boiler is ready and waiting to be started by the Sequencer Master.

Boiler has begun the start sequence but has not yet reached the boiler running status.

Boiler is running.

Boiler has left the network to service a DHW demand.

Boiler is in the process of returning to the network. For example, the slave boiler is in the Postpurge state.

Note: The recovery time is normally 30 seconds. However, if the slave boiler fails to start the recovery time increases from 30 seconds to 5, 10 and 15 minutes.

Boiler has a lockout condition and is unable to become available to the Sequencer Master.

Firing Rate:

Demanded firing rate is provided.

103448-02 - 6/13 99

Page 100

X. Operation G. Changing Adjustable Parameters (continued)

Active

Fault

Adjustment Mode

For Service Contact:

CONTRACTOR NAME

ADDRESS LINE 1 ADDRESS LINE 2

PHONE NUMBER

Access Level: Installer

Password required

Installer Password = 76

Warning! Only Qualified

Technicians Should Adjust

Controls, Contact Your

Qualified Heating Professional

Press 5-digit display to

Input Password

Press Save to enter password

000

CLRES

5432

B S

987

Press 5-digit display to

Input Password

076

After inputting the

password press to enter password

After password is Saved

These buttons access

Adjust mode screens

Service Contact Adjust

Save Adjust

Adjust

G. Changing Adjustable Parameters

1. Entering Adjust Mode

The Control is factory programmed

to include basic modulating boiler functionality. These settings are password protected to discourage unauthorized or accidental changes to settings. User login is required to view or adjust these settings:

- Press the “Adjust” button on the “Home” screen.

- Press the “Adjust” button on the Adjust Mode screen or Press Contractor for service provider contact information.

- Press “Login” button to access password screen.

- Press 5-digit display to open a keypad. Enter the password (Installer Password is 76) and press the return arrow to close the keypad. Press the “Save” button.

- Press the “Adjust” button to enter Adjustment mode.

2. Adjusting Parameters

Editing parameters is accomplished as follows:

Accept Value

Press the button to confirm newly edited value. The value modified with the increase and decrease buttons is not accepted unless this button is also pressed

Figure 56: Adjust Mode Screens

Central Heat

CH Setpoint

180

Value to be edited

(blinks while editing)

Cancel edit

Edit Value

Press the button to cancel newly edited value and go back to the original

Press the buttons to edit a value. While editing a value it will blink until it has been accepted or cancelled. A value is also cancelled by leaving the screen without accepting the value.

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