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

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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

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.

2 103448-02 - 6/13

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.

103448-02 - 6/13 3

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.

4 103448-02 - 6/13

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

103448-02 - 6/13 5

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.

6 103448-02 - 6/13

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

103448-02 - 6/13 7

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

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

8 103448-02 - 6/13

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

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

103448-02 - 6/13 9

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

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.)

10 103448-02 - 6/13

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.

103448-02 - 6/13 11

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.

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.

12 103448-02 - 6/13

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.

103448-02 - 6/13 13

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

14 103448-02 - 6/13

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

103448-02 - 6/13 15

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

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

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

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.

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

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

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

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

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

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

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

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.

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

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

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

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