Burnham ALP080 User Manual

INSTALLATION, OPERATING AND

SERVICE INSTRUCTIONS FOR

ALPINE™

CONDENSING HIGH EFFICIENCY

DIRECT VENT

GAS - FIRED HOT WATER BOILER

As an ENERGY STAR^®Partner, Burnham Hydronics has determined that the Alpine™ Series meets the ENERGY

STAR^®guidelines for energy efﬁciency 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 qualiﬁed installer, service agency or the

gas supplier. This boiler requires a special venting system. Read these instructions carefully before installing.

Price - $5.00

101602-01R2-9/08

WaRning

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

in this manual.

improperinstallation,adjustment,alteration,serviceormaintenancecancausepropertydamage,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 efﬁciency.

installation is not complete unless a pressure relief valve is installed into the tapping located on left side

of appliance. - See the Water Piping and Trim Section of this manual for details.

This boiler is supplied with safety devices which may cause the boiler to shut down and not re-start

without 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 high pressure. Do not unscrew any pipe ﬁttings 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.

Boilermaterialsofconstruction,productsofcombustionandthefuelcontainalumina,silica,heavymetals,

carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or harmful substances which can cause

death or serious injury and which are known to the state of California to cause cancer, birth defects and

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

or working nearby the appliance.

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

tions, including all those contained in component manufacturers manuals which are provided with the

boiler before installing, starting up, operating, maintaining or servicing.

Keep boiler area clear and free from combustible materials, gasoline and other ﬂammable vapors or

liquids.

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 printed on the back of this manual. it is the responsibility

of the installing contractor to see that all controls are correctly installed and are operating properly when the

installation is complete.

ꢀ

Table of Contents

I. Product Description, Speciﬁcations

VIII. Electrical.......................................49

IX. Boiler Stacking .............................56

X. Modular Installation ....................58

XI. System Start-up ............................66

XII. Operation.....................................72

XIII. Service and Maintenance..............84

XIV. Troubleshooting ...........................88

XV. Repair Parts..................................91

and Dimensional Data....................4

II. Pre-Installation...............................8

III. Unpacking Boiler ...........................9

IV. Venting.........................................10

V. Condensate Disposal ....................29

VI. Water Piping and Trim .................31

VII. Gas Piping....................................46

I. Product Description, Speciﬁcations and Dimensional Data

Alpine™ Series boilers are condensing high efﬁciency

gas-ﬁred direct vent hot water boilers designed for use

in forced hot water space or space heating with indirect

domestic hot water heating systems, where supply water

temperature does not exceed 210°F. These boilers have

special coil type stainless steel heat exchangers, constructed,

tested and stamped per Section IV ‘Heating Boilers’ of

ASME Boiler and Pressure Vessel Code, which provide a

maximum heat transfer and simultaneous protection against

ﬂue gas product corrosion. These boilers are not designed

for use in gravity hot water space heating systems or

systems containing signiﬁcant amount of dissolved oxygen

(swimming pool water heating, direct domestic hot water

heating, etc.).

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

Boiler Model

Dimension

ALP080

ALP105

ALP150

ALP210

ALP285

ALP399

28-7/8

(734)

A - Inch

12-9/16

19-11/16

23-15/16

21-13/16

(554)

(mm)

(320)

(356)

(500)

(608)

B - Inch

5-5/8

5-13/16

7-5/16

6-3/16

(mm)

(142)

(147)

(185)

(157)

C - Inch

7-5/16

14-1/8

13-1/16

(mm)

(186)

(358)

(332)

D - Inch

9-5/16

10-3/4

16-7/16

17-1/8

23-3/4

(mm)

(237)

(273)

(417)

(435)

(456)

(602)

E - Inch

5-15/16

12-1/4

15-13/16

(mm)

(151)

(312)

(402)

Gas Inlet F

(FPT)

1/2”

1”

3/4”

1”

Return G

(FPT)

1-1/4”

1-1/2”

Supply H

(FPT)

1”

* Factory Provided Socket End Compression Pipe Joining Clamp

Condensate Drain J *

for 3/4” Schedule 40 PVC Pipe

Boiler Two Pipe

CPVC/PVC Vent Connector

- Inch

3 x 3

3 x 4

4 x 4

Approx. Shipping Weight

(LBS)

137

155

182

206

256

304

ꢁ

Table 2a: Rating Data - Models aLP080 thru aLPꢀ99 (0 to 2000 Feet Elevation above Sea Level)

alpine Series gas-Fired Boilers

Input

(MBH)

Heat Transfer

Area

Net I=B=R

Ratings

Water (MBH)

Thermal

Efﬁciency

(%)

Boiler Water

Volume

* Model

Number

** Output

(MBH)

AFUE

Combustion

Efﬁciency (%)

(Gal.)

(Sq. Ft.)

Min. Max.

ALP080

ALP105

ALP150

ALP210

ALP285

ALP399

0.6

0.7

1.3

1.7

2.4

3.4

7.3

9.1

105

150

210

285

399

138

194

265

377

120

169

230

328

16.4

21.8

29.1

41.8

94.1

94.5

* Add Sufﬁx “N” for Natural Gas or Sufﬁx “P” for LP Gas Models.

notes: ** DOE Heating Capacity (ALP080 thru ALP285); Gross Output (ALP399)

Maximum Working Pressure, Water - 30 PSI Shipped from Factory (std.); 50 PSI - Optional (ALP080 thru ALP285)

Maximum Working Pressure, Water - 50 PSI Shipped from Factory (std.); (ALP399)

Maximum Allowable Temperature, Water - 210°F

Boilers are factory shipped as Natural Gas builds and have to be ﬁeld adjusted for LP gas application. Refer to ‘System Start-

Up Section of this manual for detailed procedure.

Ratings shown are for installations at sea level and elevations up to 2000 Feet. For elevations above 2000 Feet, ratings should be

reduced at the rate of four percent (4%) for each 1000 Feet above sea level.

Table 2B: Rating Data - Models aLP080 thru aLPꢀ99 (2001 to ꢂ000 Feet Elevation above Sea Level)

alpine Series gas-Fired Boilers

Input

(MBH)

Net I=B=R

Ratings

Water (MBH)

Thermal

Efﬁciency

(%)

Boiler Water

Volume

Model

Number *

** Output

(MBH)

AFUE

Combustion

Efﬁciency (%)

Heat Transfer

Area (Sq. Ft.)

(Gal.)

Min. Max.

ALP080

ALP105

ALP150

ALP210

ALP285

ALP399

0.6

0.7

1.3

1.7

2.4

3.4

7.3

9.1

105

150

210

285

399

138

194

265

377

120

169

230

328

16.4

21.8

29.1

41.8

94.1

94.5

* Add Sufﬁx “N” for Natural Gas or Sufﬁx “P” for LP Gas Models.

notes: ** DOE Heating Capacity (ALP080 thru ALP285); Gross Output (ALP399)

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 and have to be ﬁeld adjusted for LP gas application. Refer to ‘System Start-

Up Section of this manual for detailed procedure.

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

ꢂ

ii. Pre-installation

WaRning

2. Access is provided to the condensate trap located

underneath the heat exchanger.

if you do not follow these instructions exactly,

a ﬁre or explosion may result causing property

damage or personal injury.

D. Install on level ﬂoor. For basement installation provide

a solid base such as concrete, if ﬂoor is not level or if

water may be encountered on ﬂoor around boiler. Floor

must be able to support weight of boiler, water and all

additional system components.

DangER

E. Protect gas ignition system components from water

(dripping, spraying, rain, etc.) during boiler operation

and service (circulator replacement, condensate trap,

control replacement, etc.).

Do not install boiler where gasoline or other

ﬂammable vapors or liquids, or sources of

hydrocarbons (i.e. bleaches, cleaners, chemicals,

sprays, paint removers, fabric softeners, etc.) are

used or stored.

F. 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.

nOTiCE

Due to the low water content of the boiler, mis-

sizing of the boiler with regard to the heating

system load will result in excessive boiler cycling

and accelerated component failure. Burnham

DOES nOT warrant failures caused by mis-sized

boiler applications. DO nOT oversize the boiler to

the system. Modular boiler installations greatly

reduce the likelihood of boiler oversizing.

WaRning

Adequate combustion and ventilation air must

be provided to assure proper combustion.

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

length of the vent system. The PVC combustion

air piping, or the optional concentric vent piping,

containing integral combustion air inlet piping, must

terminate where outdoor air is available for combustion

and away from areas that may contaminate combustion

air. In particular, avoid areas near chemical products

containing chlorines, chloro/ﬂuorocarbons, paint

removers, cleaning solvents and detergents. Avoid

areas containing saw dust, loose insulation ﬁbers, dry

wall dust etc.

A. Installation must conform to the requirements of the

authority having jurisdiction. In the absence of such

requirements, installation must conform to the National

Fuel Gas Code, NFPA 54/ANSI Z223.1, and/or CAN/

CSA B149.1 Installation Codes.

B. Appliance is design certiﬁed for installation on

combustible ﬂooring. Do not install boiler on

carpeting.

C. Provide clearance between boiler jacket and

combustible material in accordance with local ﬁre

ordinance. Refer to Figure 2 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:

CaUTiOn

avoid operating this boiler in an environment

where saw dust, loose insulation ﬁbers, 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.

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

removable front access panel.

Figure 2: Clearances To Combustible and non-combustible Material

iii. Unpacking Boiler

CaUTiOn

D. Remove boiler from cardboard positioning sleeve on

shipping skid.

Do not drop boiler.

WaRning

A. Move boiler to approximate installed position.

B. Remove all crate fasteners.

installation of this boiler should be undertaken

only by trained and skilled personnel from a

qualiﬁed service agency.

C. Lift and remove outside container.

E. Move boiler to its permanent location.

iV. Venting

WaRning

Failure to vent this boiler in accordance with these instructions could cause products of combustion to

enter the building resulting in severe property damage, personal injury or death.

Do not interchange vent systems or materials unless otherwise speciﬁed.

The use of thermal insulation covering pipe and ﬁttings is prohibited.

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

The use of CPVC is required when venting in chase ways and through interior wall penetrations.

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 vent termination where chlorines, chloro/ﬂuorocarbons (CFC’s), petroleum distillates,

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

result.

The use of cellular core PVC (aSTM F891) is prohibited.

Do not locate vent termination under a deck.

Do not reduce size of vent/combustion air pipe diameter.

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

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

4. Place in operation the appliance being inspected.

Follow the Lighting (or Operating) Instructions.

Adjust thermostat so appliance will operate

continuously.

A. Vent Guidelines Due to Removal of an Existing

Boiler

For installations not involving the replacement of an

existing boiler, proceed to Step B.

5. Test for spillage at the draft hood relief opening

after ﬁve (5) minutes of main burner operation. Use

the ﬂame of a match or candle, or smoke from a

cigarette, cigar or pipe.

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:

6. After it has been determined that each appliance

remaining connected to the common venting system

properly vents when tested as outlined above, return

doors, windows, exhaust fans, ﬁreplace dampers and

any other gas burning appliance to their previous

conditions of use.

1. Seal any unused openings in the common venting

system.

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.

2. Visually inspect the venting system for proper

size and horizontal pitch and determine there is no

blockage or restriction, leakage, corrosion, and other

deﬁciencies 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 maximum

speed. Do not operate a summer exhaust fan. Close

ﬁreplace dampers.

B. 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 ﬁre ofﬁcials about

restrictions and installation inspection in your area.

2. The Alpine™ is designed to be installed as a Direct

Vent boiler. The air for combustion is supplied

directly to the burner enclosure from outdoors and

ﬂue gases are vented directly outdoors (through wall

or roof).

See Table 6 for complete list of Burnham Vent

System Components. Use single wall thimble

[Burnham Part No. 102180-01 (3”), 102181-01 (4”)]

when penetrating a combustible wall for vent only.

1. Horizontal vent pipe must maintain a minimum ¼

inch per foot slope down towards boiler.

3. The following combustion air/vent system options

are approved for use with the Alpine™ boilers:

2. Use noncombustible ¾ inch pipe strap to support

horizontal runs and maintain vent location and slope

while preventing sags in pipe. Maximum support

spacing is four (4) feet. Avoid low spots where

condensate may pool. Do not penetrate any part of

the vent system with fasteners.

i. Two-Pipe CPVC/PVC Gas Vent/Combustion

Air System (factory standard) - separate

CPVC/PVC pipe serves to expel products of

combustion and separate PVC pipe delivers fresh

outdoor combustion air. Refer to Paragraph C

through F for speciﬁc details.

WaRning

ii. Combination Concentric Gas Vent/

Combustion Air Inlet (optional) - the assembly

consists of inner ﬁre 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 Paragraphs G through P for

speciﬁc details.

all condensate that forms in the vent must be

able to drain back to the boiler.

3. Vent length restrictions are based on equivalent

length of vent/combustion air pipe (total length

of straight pipe plus equivalent length of ﬁttings).

Maximum vent/combustion air lengths are listed in

Table 7. Do not exceed maximum vent/combustion

air lengths. Table 6 lists equivalent lengths for

ﬁttings. Do not include vent/combustion air

terminals in equivalent feet calculations. See

“Combustion Air/Vent, Equivalent Length Work

Sheet”.

4. Refer to Table 3 and the appropriate drawings to

determine the proper conﬁguration of either factory

standard or optional venting/combustion air system

details.

C. The following information is applicable for Two-

Pipe CPVC/PVC Gas Vent/Combustion Air System

(factory standard).

4. Provide minimum service clearance between boiler

back and concentric vent exiting through outside

wall, for concentric vent installation/replacement

and/or ﬂue temperature sensor service/replacement.

WaRning

5. Do not install venting system components on

the exterior of the building except as speciﬁcally

required by these instructions. The vent termination

location is restricted as follows (refer to Figures 6

and 9):

all CPVC vent components (supplied with boiler)

must be used for near-boiler vent piping before

transitioning to Schedule ꢁ0 PVC pipe (aSTM

2665) components for remainder of vent system.

CPVC vent components must be used prior to

exit of any closet or conﬁned space.

a. Minimum twelve (12) inches above grade plus

normally expected snow accumulation level, or

seven (7) feet above grade, if located adjacent

Table ꢀ: Combustion air/Vent System Options

additional Components

installation

Option

Description

Vent Kit

included with Drawing and

Required

Boiler

Speciﬁcation

Direct Vent (sealed combustion) with both the vent pipe and

combustion air pipe terminating horizontally (through a sidewall)

with individual penetrations for the vent and combustion air

piping and terminals.

TWO-PiPE

CPVC/PVC

HORizOnTaL

See Table ꢁ

See Figure 6

Direct Vent (sealed combustion) with both the vent pipe and

combustion air pipe terminating vertically (through the roof) with

individual penetrations for the vent and combustion air piping

and terminals.

TWO-PiPE

CPVC/PVC

VERTiCaL

See Figures

9 and 10

See Table ꢁ

COnCEnTRiC

HORizOnTaL

Direct Vent (sealed combustion) the concentric vent pipe

terminates horizontally (through a sidewall).

See Table 9

See Figure 1ꢀ

COnCEnTRiC

VERTiCaL

Direct Vent (sealed combustion) the concentric vent pipe

terminates vertically (through the roof).

Yes

See Table 9

See Figure 19

Table ꢁ: Vent System Components included with Boiler

Quantity

Part

Vent System Components

Number

ALP080 & ALP105 ALP150 & ALP210 ALP285 & ALP399

(P/N 102189-01)

(P/N 102189-02)

(P/N 102189-03)

3” Schedule 40 PVC Tee Combustion Air/Vent Terminal

4” Schedule 40 PVC Tee Combustion Air/Vent Terminal

3” Stainless Steel Rodent Screens

102190-01

102190-02

102191-01

102191-02

102193-01

102193-02

102192-01

102192-02

102195-01

102194-01

102188-01

102183-01

102183-02

102183-03

102185-01

102185-02

102153-01

---

4” Stainless Steel Rodent Screens

---

3” x 30” Schedule 40 CPVC Pipe

---

4” x 30” Schedule 40 CPVC Pipe

---

3” Schedule 80 CPVC 90° Elbow

---

4” Schedule 80 CPVC 90° Elbow

---

8 oz. Bottle of Transition Cement

8 oz. Bottle of Primer

Burnham Vent Supplement Manual

Two Pipe Vent System Connector for CPVC/PVC

Two Pipe Vent System Connector for CPVC/PVC Gasket

Silicone Vent Sensor Cap

---

Table 5: Clearances from Vent Piping to Combustible Material

Minimum Clearance To

Combustible Material, Inches

Vent Pipe

Pipe Direction

Enclosure

CPVC/PVC Venting

Vertical or Horizontal

Enclosed at all Sides

1” Vent/0” Combustion Air

Table 6: Burnham Vent System and Combustion air System Components

Vent System Component

3” Schedule 40 CPVC Pipe x 30 Inches

4” Schedule 40 CPVC Pipe x 30 Inches

3” Schedule 80 CPVC 90° Elbow

Equivalent Length (Ft.)

Combustion Air

System Component

(Parts by Others)

Equivalent

Feet of Pipe*

2.5

3” or 4” ID Pipe x 1 Ft.

3” or 4” ID Pipe x 2 Ft.

3” or 4” ID Pipe x 4 Ft.

3” or 4” ID Pipe x 5 Ft.

3” or 4” 90° Elbow

4” Schedule 80 CPVC 90° Elbow

Maximum Number of 90’s and Straight Pipe

# of 90’s

Vent Pipe

3” or 4” 45° Elbow

Feet of Pipe 55

*Equivalent Feet of Pipe Based on

Standard 4” PVC Design

# of 90’s

Combustion

Air Pipe

Feet of Pipe 55

This distance may be reduced if equipment is

protected from damage due to condensation or

vapor by enclosure, overhangs, etc.

to public walkway. Do not install over public

walkway where local experience indicates

appliance ﬂue gas vapor or condensate creates a

nuisance or hazard.

e. Minimum twelve (12) inches from overhang or

corner of building.

b. Minimum three (3) feet above any forced

combustion air located within ten (10) feet.

6. Enclose vent passing through occupied or

unoccupied spaces above the boiler with material

having a ﬁre resistance rating of at least equal to the

rating of the adjoining ﬂoor or ceiling. Maintain

minimum clearances to combustible materials. See

Figure 2 and Table 5 for details.

c. Direct Vent - Minimum one (1) foot below, one

(1) foot horizontally from, or one (1) foot above

any door, window, or gravity air inlet.

d. Minimum four (4) feet horizontally from electric

meters, gas meters, regulators, and relief valves.

Table ꢂ: Vent/Combustion air Pipe Length

3” Combustion Air Pipe

(Equivalent Length)

4” Combustion Air Pipe

(Equivalent Length)

3” Vent Pipe

(Equivalent Length)

4” Vent Pipe

(Equivalent Length)

Boiler

Model

Min.

Max.

60 Ft.

---

Min.

---

Max.

---

Min.

21-7/8 In.

---

Max.

60 Ft.

---

Min.

---

Max.

---

ALP080

ALP105

ALP150

ALP210

ALP285

ALP399

21-7/8 In.

---

21-7/8 In.

32 In.

60 Ft.

---

32 In.

60 Ft.

---

Combustion Air/Vent, Equivalent Length Work Sheet

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

Combustion air

Vent

90° elbow(s) PVC

Supplied 30” straight CPVC

Length ft. = 2.5

Quantity =

x 5’ =

x 2.5’ =

x 1 =

equiv. ft. a.

equiv. ft. b.

equiv. ft. c.

x 1 =

2.5

equiv. ft. a.

equiv. ft. b.

equiv. ft. c.

equiv. ft. d.

45° elbow(s) PVC

Supplied 90° elbow CPVC

Quantity =

x 5’ =

Straight pipe PVC

90° elbow(s) PVC

Length ft. =

Quantity =

45° elbow(s) PVC

Quantity =

x 2.5’ =

x 1 =

Straight pipe PVC

Length ft. =

equiv. ft. e.

equiv. ft.

Total*

a.+b.+c. =

equiv. ft.

Total*

a.+b.+c.+d.+e.=

* Total cannot exceed 60 equiv. ft. length.

Vent and combustion air terminals do not count towards total equiv. ft.

Note: For one or two family dwellings, ﬁre

resistance rating requirement may not need to be

met, but is recommended.

vent connector mounting hardware - six (6) #8 x ½”

black oxide round head Phillips sheet metal screws - are

shipped inside Miscellaneous Part Carton.

7. Plan venting system to avoid possible contact with

plumbing or electrical wires. Start at vent connector

at rear of boiler and work towards vent termination.

1. Remove the vent connector and gasket from the vent

carton.

2. Locate six mounting screws.

8. Design the Vent System to allow a 3/8” of thermal

expansion per 10 feet of CPVC/PVC pipe. Runs of

20 ft. or longer that are restrained at both ends must

use an offset or expansion loop. Refer to Figure 3.

3. Position the vent connector and gasket onto jacket

combination rear/bottom panel and insert vent

connector inner stainless steel vent pipe into the heat

exchanger vent outlet.

9. Follow all manufacturer instructions and warnings

when preparing pipe ends for joining and using the

primer and the cement.

4. Align vent connector plate and gasket clearance

holes with rear/bottom panel engagement holes; then

secure the collar and gasket to rear/bottom panel

with six mounting screws. See Figure 4.

D. Installation of Two-Pipe CPVC/PVC Gas Vent/

5. Flue temperature sensor, factory attached to the

boiler wiring harness, is secured to the boiler rear/

bottom panel with tape.

Combustion Air System Connector

The boiler two pipe vent system connector for CPVC/

PVC and gasket are shipped inside the vent carton. The

1ꢀ

Figure ꢀ: Expansion Loop and Offset

6. Remove the Silicone ﬂue sensor cap from the vent

b. Clean all vent and combustion air pipe joints

with primer and secure with transition cement,

(8 oz. bottle of primer and 8 oz. bottle of

transition cement supplied with boiler). Follow

the instructions provided on the primer and

cement.

carton and press onto the two pipe vent system

connector for CPVC/PVC sensor port. Remove

the tape holding the ﬂue sensor and insert the ﬂue

temperature sensor into the ﬂue sensor plug until it

is ﬁrmly engaged. See Figure 4.

7. Near-Boiler Vent Piping (see Figure 5):

E. CPVC/PVC Horizontal Venting System

See Figures 3 thru 8.

WaRning

Vent Piping - Horizontal

all CPVC vent components (supplied with boiler)

must be used for near-boiler vent piping before

transitioning to Schedule ꢁ0 PVC pipe (aSTM

2665) components for remainder of vent system.

1. See Paragraph D for instructions on attaching the

vent system connector to the boiler.

2. Do not exceed maximum vent length. Refer to

Table 7 for pipe diameters and allowable lengths.

3. Horizontal vent pipe must maintain a minimum ¼

inch per foot slope down towards boiler.

a. All CPVC vent components (supplied with

boiler), 30” straight and 90° elbow, must be

used for near-boiler piping before transitioning

to Schedule 40 PVC (ASTM 2665) pipe

components for remainder of vent system.

The CPVC 30” straight section may be cut to

accommodate desired vent conﬁguration for

near-boiler piping, provided both pieces are used

in conjunction with the CPVC 90° elbow, before

any PVC components are used. Ensure that the

CPVC elbow is the ﬁrst elbow used in the vent

system as it exits the boiler.

4. Use appropriately designed thimbles when passing

through combustible walls (thimble use is optional

for noncombustible walls). Insert thimble through

wall from outside. Secure outside ﬂange to wall

with nails or screws, and seal ID, OD and vent holes

with sealant material. Install inside ﬂange to inside

wall, secure with nails or screws, and seal with

sealant material.

5. For noncombustible wall application when thimble

is not used, size opening such that a minimal

clearance is obtained.

1ꢁ

Figure ꢁ: Field installation of Two Pipe Vent System Connector for CPVC/PVC

Figure 5: near-Boiler Vent/Combustion air Piping

6. Install Rodent Screen and Vent Terminal (supplied

3. Horizontal combustion air pipe must maintain a

minimum ¼ inch per foot slope down towards

terminal, when possible. If not, slope toward boiler.

with boiler), see Figure 8 for appropriate

conﬁguration.

7. Apply sealant between vent pipe and opening/

thimble to provide weather-tight seal. Sealant

should not restrain the expansion of the vent pipe.

4. It is strongly recommended to locate the combustion

air terminal on the same wall as the vent termination

to prevent nuisance boiler shutdowns. Combustion

air terminal can be installed closer to wall than vent.

Combustion Air Piping - Horizontal

1. See Paragraph D for instructions on attaching the

5. Start at vent connector (rear boiler jacket) and work

towards the combustion air terminal.

vent system connector to the boiler.

2. Do not exceed maximum combustion air length.

Refer to Table 7 for pipe diameters and allowable

lengths.

6. Size combustion air wall penetration to allow easy

insertion of combustion air piping.

7. Install Rodent Screen and Combustion Air Terminal

(supplied with boiler), see Figure 8 for appropriate

conﬁguration.

8. Apply sealant between vent pipe and opening to

provide weather-tight seal

F. CPVC/PVC Vertical Venting System

Refer to Figures 3, 4, 5, 8, 9 & 10.

nOTiCE

Roof penetrations require the use of roof ﬂashing

and storm collar that are not supplied with boiler.

Vent Piping - Vertical

1. See Paragraph D for instructions on attaching the

vent system connector to the boiler.

2. Do not exceed maximum vent length. Refer to

Table 7 for pipe diameters and allowable lengths.

3. Horizontal vent pipe must maintain a minimum ¼

inch per foot slope down towards boiler.

4. Install ﬁre stops where vent passes through ﬂoors,

ceilings or framed walls. The ﬁre stop must close

the opening between the vent pipe and the structure.

5. Whenever possible, install vent straight through the

roof. Refer to Figures 9 and 10.

Figure 6 : Direct Vent - Side Wall Terminations

Figure ꢂ: Location of Vent Terminal Relative to Windows, Doors, grades,

Overhangs, Meters and Forced air inlets (Combustion air Terminal not shown)

Figure 8: Rodent Screen installation

a. Size roof opening to maintain minimum

clearance of 1 inch from combustible materials.

b. Extend vent 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.

CaUTiOn

Vertical venting requires the use of roof ﬂashing

and a storm collar to prevent moisture from

entering the structure.

c. Install storm collar on vent pipe immediately

above ﬂashing. Apply Dow Corning Silastic 732

RTV Sealant between vent pipe and storm collar

to provide weather-tight seal.

6. Install Rodent Screen and Vent Terminal (supplied

with boiler), see Figure 8 for appropriate

conﬁguration.

Figure 9: Direct Vent - Vertical Terminations

Figure 10: Direct Vent - Vertical Terminations with Sloped Roof

Extend vent/combustion air piping to maintain minimum vertical (‘X’) and minimum horizontal (‘Y’) distance of

twelve (12) inches (18 inches Canada) from roof surface. allow additional vertical (‘X’) distance for expected

snow accumulation.

1ꢂ

7. Brace exterior piping if required.

Vent Piping - Snorkel

1. See Paragraph D for instructions on attaching the

Combustion Air Piping - Vertical

1. See Paragraph D for instructions on attaching the

vent system connector to the boiler.

2. Do not exceed maximum vent length. Refer to

Table 7 for pipe diameters and allowable lengths.

2. Do not exceed maximum combustion air length.

Refer to Table 7 for pipe diameters and allowable

lengths.

3. Horizontal vent pipe must maintain a minimum ¼

inch per foot slope down towards boiler

3. Horizontal combustion air pipe must maintain a

minimum ¼ inch per foot slope down towards

boiler.

4. After penetrating wall/thimble, install a Schedule

40 PVC 90° elbow so that the elbow leg is in the up

direction.

4. 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.

5. Install maximum vertical run of seven (7) feet of

Schedule 40 PVC vent pipe. See Figure 11.

5. Start at vent connector on burner enclosure (rear

boiler jacket) and work towards the combustion air

terminal.

6. Size roof opening to allow easy insertion of

combustion air piping and allow proper installation

of ﬂashing and storm collar to prevent moisture

from entering the structure.

a. Use appropriately designed vent ﬂashing

when passing through roofs. Follow ﬂashing

manufacturers’ instructions for installation

procedures.

b. 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.

c. Install storm collar on combustion air pipe

immediately above ﬂashing. Apply Dow

Corning Silastic 732 RTV Sealant between

combustion air pipe and storm collar to provide

weather-tight seal.

Figure 11: Direct Vent - Optional Side Wall

Snorkel Terminations

6. At top of vent pipe length install another PVC 90°

elbow so that elbow leg is opposite the building’s

exterior surface.

7. Install Rodent Screen and Combustion Air Terminal

(supplied with boiler), see Figure 8 for appropriate

conﬁguration.

8. Brace exterior piping if required.

7. Install Rodent Screen and Vent Terminal (supplied

with boiler), see Figure 8 for appropriate

conﬁguration.

G. Optional Snorkel CPVC/PVC Horizontal Vent

System

8. Brace exterior piping if required.

Refer to Figures 3, 4, 5, 7, 8 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 (Section E).

Combustion Air Piping - Snorkel

1. See Paragraph D for instructions on attaching the

vent system connector to the boiler.

2. Do not exceed maximum combustion air length.

Refer to Table 7 for pipe diameters and allowable

lengths.

nOTiCE

Exterior run to be included in equivalent vent/

combustion air lengths.

3. Horizontal combustion air pipe must maintain a

minimum ¼ inch per foot slope down towards

terminal, when possible. If not, slope toward boiler.

4. After penetrating wall, install a Schedule 40 PVC

90^oelbow so that elbow leg is in the up direction.

2. Remove the collar from the bag and set aside.

3. Locate and remove six mounting screws.

5. Install maximum vertical run of seven (7) feet of

Schedule 40 PVC vent pipe. See Figure 11.

6. At top of vent pipe length install another PVC 90°

elbow so that elbow leg is opposite the building’s

exterior surface.

4. Position the Collar onto jacket combination rear/

bottom panel and insert collar inner stainless steel

vent pipe into the heat exchanger vent outlet.

7. Install Rodent Screen and Combustion Air Terminal

(supplied with boiler), see Figure 8 for appropriate

conﬁguration.

5. 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 12.

8. Brace exterior piping if required.

6. Flue temperature sensor, factory attached to the

boiler wiring harness, is secured to the boiler rear/

bottom panel with tape.

H. The following information is applicable for

Combination Concentric Gas Vent/Combustion air

System (optional).

7. Remove the tape and push the sensor rubber plug

into Concentric Vent Collar sensor port until the

plug is securely engaged. See Figure 12.

I. Field Installation of Boiler Concentric Vent Collar

The Boiler Concentric Vent Collar is shipped inside the

boiler in plastic bag. The Collar mounting hardware

- six (6) #8 x ½” black oxide round head Phillips sheet

metal screws - are shipped inside Miscellaneous Part

Carton.

The installation of the Concentric Vent Collar is now

completed.

J. General Guidelines - Concentric Venting

1. Release four side draw latches and remove boiler

lower front door assembly to gain access to the Vent

Collar.

1. Vent system installation must be in accordance

with National Fuel Gas Code, NFPA 54/ANSI

Z221.3 or applicable provisions of local building

Table 8: Concentric Vent Components

Component

Part Number

Component Description

90° Elbow – Long Radius

Size

Equivalent Vent

Length, Ft

5.5

Comments

101493-01

101491-01

101163-01

101162-01

101485-01

101808-01

101495-01

101496-01

101497-01

101492-01

101498-01

101548-01

101549-01

101550-01

101551-01

101553-01

101809-01

101557-01

101558-01

101559-01

101560-01

101561-01

notes:

80/125 mm

100/150 mm

45° Elbow - Long Radius

3.0

Cut -To-Length Extension, 500 mm (19-1/2”)

Cut -To-Length Extension, 1000 mm (39”)

Fixed Extension, 2000 mm (78”)

Horizontal (Wall) Terminal

1.63

3.25

*NA

**Can be cut

***Must not be cut

Supplied with boiler

See Note 1

Vertical Roof Terminal

Flat Roof Flashing

Sloped Roof Flashing

See Note 2

See Note 3

Support Elbow with Chimney Chase Bracket

Hanger Wall Bracket

8.5

90° Elbow – Long Radius

8.0

3.0

45° Elbow - Long Radius

1 Cut -To-Length Extension, 500 mm (19-1/2”)

Cut -To-Length Extension, 1000 mm (39”)

Fixed Extension, 2000 mm (78”)

Horizontal (Wall) Terminal

1.63

3.25

6.5

** Can be cut

*** Must not be cut

Supplied with boiler

See Note 1

* NA

Vertical (Roof) Terminal

Flat Roof Flashing

Sloped Roof Flashing

See Note 2

See Note 3

Support Elbow with Chimney Chase Bracket

Hanger Wall Bracket

10.0

* NA – do not include vent terminal into total vent length calculations.

** These sections have plain male end and beaded female end. See Figure 11 for details.

*** These sections have beaded male end and beaded female end. See Figure 12 for details.

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

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

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

Figure 12: Field installation of Boiler Concentric Vent Collar

codes. Contact local building or ﬁre ofﬁcials about

restrictions and installation inspection in your area.

5. Provide and maintain vent pipe minimum clearances

to combustible material. See Figure 2 and Table 10

for details.

2. Horizontal vent pipe must maintain a minimum ¼

inch per foot slope towards the boiler.

6. Provide minimum service clearance between boiler

back and concentric vent exiting through outside

wall, for concentric vent installation/replacement

and/or ﬂue temperature sensor service/replacement,

as follows:

3. Use noncombustible ¾ inch 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 is ﬁve (5) feet. Do not

penetrate any part of the vent system with fasteners.

a. For horizontal venting where supplied

Concentric Vent Terminal is attached directly to

installed Boiler Concentric Vent Collar - 6 inches

4. Vent length restrictions are based on equivalent

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

plus equivalent length of ﬁttings. See Table 11

for speciﬁed vent length details. Do not exceed

maximum vent length. Table 8 lists available

concentric vent components and includes equivalent

vent length for ﬁttings. Do not include vent terminal

into total vent length calculations.

b. For vertical venting where optional Concentric

Vent 90° long radius elbow is attached to

installed Boiler Concentric Vent Collar - 18

inches

7. Do not install venting system components on the

exterior wall of the building except as speciﬁcally

required by these instructions. Refer to Figure 7.

Table 9: Vent System Components included with Boiler

Vent System Components

Part Number

101808-01

80/125mm Horizontal (Wall) Terminal (ALP080 thru ALP210)

100/150mm Horizontal (Wall) Terminal (ALP285 thru ALP399)

101809-01

Table 10: Clearances from Vent Piping to Combustible Material

Minimum Clearance To

Enclosure

Vent Pipe

Pipe Direction

Combustible Material, Inches

CPVC/PVC Venting

Vertical Or Horizontal

Enclosed at All Sides

1” Vent/0” Combustion Air

Table 11: Concentric Vent Length

Vent Length

Inner/Outer Pipe

Boiler Model

Concentric Vent

Wall Opening Diameter

Dia., mm

Minimum

* Maximum

ALP080

ALP105

ALP150

ALP210

ALP285

ALP399

Factory Supplied

Horizontal (Wall) Terminal

80/125 mm

21-7/8 in

32 in

5-1/2 in

6-1/2 in

Total of 60

Equivalent ft.

Factory Supplied

Horizontal (Wall) Terminal

100/150 mm

note: * With optional concentric vent components. See Table 10 for details.

2. Concentric Vent components supplied with the boiler

are packed inside boiler carton and include the

following:

The direct vent termination location is restricted as

follows:

a. Minimum twelve (12) inches above grade plus

normally expected snow accumulation level, or

minimum seven (7) feet above grade, if direct

vent terminal is located adjacent to public

walkway. Do not install the terminal over public

walkway where local experience indicates that

appliance ﬂue gas vapor or condensate creates a

nuisance or hazard.

a. 80/125 mm Horizontal (Wall) Terminal, Part

Number 101808-01

•

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”.

b. Minimum three (3) feet above any forced air

inlet located within ten (10) feet.

•

Separate Inside Wall Plate

c. Minimum four (4) feet horizontally from electric

meters, gas meters, regulators and relief valves.

This distance may be reduced if equipment is

protected from damage due to ﬂue gas vapor or

condensation by enclosure, overhang, etc.

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.

d. Minimum twelve (12) inches below, above or

horizontally from any air opening into a building

(window, door or gravity air inlet).

b. 100/150 mm Horizontal (Wall) Terminal, Part

Number 101809-01

•

Horizontal Concentric Vent Terminal, which

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 31-1/8”.

e. Minimum twelve (36) inches horizontally from a

building corner.

f. 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 ﬂue vapor condensation.

•

Separate Inside Wall Plate.

8. Enclose vent passing through occupied or

unoccupied spaces above the boiler with material

having a ﬁre resistance rating of at least equal to the

rating of the adjoining ﬂoor or ceiling. Maintain

minimum clearances to combustible materials. See

Figure 2.

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.

14. Installation of the Boiler Concentric Vent Collar is

covered in Section I above. See Figure 12.

Note: For one or two family dwellings, ﬁre

resistance rating requirement may not need to be

met, but is recommended.

15. For horizontal (side wall) installation, the Horizontal

(Wall) Terminal will extend past outer wall surface

either by 4-1/4” (80/125 mm), or, 5-1/2” (100/150

mm). See Figure 13 “Horizontal (Wall) Terminal

Installation”.

9. Plan venting system to avoid possible contact with

plumbing or electrical wires. Start at vent connector

on top of boiler and work towards vent terminal.

17. For horizontal venting, to install the Horizontal

(Wall) Terminal:

Concentric Venting - Horizontal Venting

a. Cut a 5-1/2” diameter hole through the exterior

wall opening (for 80/125 mm concentric vent) or

6-1/2” diameter hole (for 100/150 mm concentric

vent) at the planned location of the horizontal

1. Permitted terminals for horizontal venting:

Horizontal (Wall) Terminal, either 80/125 mm (P/N

101808-01) or 100/150 mm (P/N 101809-01) - see

Table 8.

terminal.

several marks around the outer pipe to establish a

cut line. See Figure 15 ‘ Cutting Outer Pipe’.

d. 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 deburred.

Figure 15: Cutting Outer Pipe

e. Mark the end of the Horizontal (Wall) Terminal

inner polypropylene vent pipe to extend ¾” past

the cut end of the outer pipe. To achieve a square

cut of the inner pipe, place several marks around

the inner pipe to establish a cut line.

f. Cut off the marked end of inner polypropylene

vent pipe with a ﬁne tooth blade hacksaw etc.

and deburr. See Figure 16 “Cutting Inner Pipe.

Figure 1ꢀ: Horizontal (Wall) Terminal installation

g. Place a mark around the outer pipe, 1” from cut

edge, towards the attached Outside Wall Plate, to

establish visual insertion line as shown in Figure

16 “Cutting Inner Pipe”.

b. Measure dimension “L” from exterior wall outer

surface to the end of the last ﬁtting (or end of

installed Boiler Concentric Vent Collar). See

Figure 14 ‘Dimension “L”’.

h. Pass the shortened Horizontal Concentric Vent

from outside, thru earlier cut exterior wall

opening and push in until the attached Outside

Wall Plate is tight against exterior wall surface.

Insure the proper position of the Horizontal

Concentric Vent before securing the Outside Wall

Plate to the wall with provided fasteners. Seal

plate edges with exterior grade sealant to prevent

moisture penetration.

Figure 1ꢁ: Dimension “L”

c. When factory supplied Horizontal (Wall)

Terminal needs to be shortened, measure

dimension “L” plus 1-¼” 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

Figure 16: Cutting inner Pipe

Concentric Venting - Vertical Venting

WaRning

For vertical (through the roof) venting, extend

Vertical (Roof) Terminal to maintain minimum 12

inches vertical and horizontal distance from building

roof surface. Allow additional vertical distance

for expected snow accumulation. Provide brace as

required. See Figure 19 ‘Vertical Concentric Vent

Installation’.

The terminal vent portion is offset towards the top

inside the outer pipe of the Horizontal Concentric

Vent Terminal to provide vent pipe pitch towards

the boiler for condensate removal.

See Figure 1ꢂ ‘Horizontal (Wall) Terminal Detail’.

it is imperative to properly mount the vent

terminal.

The terminal orientation label is located on the

inside of the terminal Outside Wall Plate. insure

the vent terminal is positioned as shown in

Figure 18 before securing the Outside Wall Plate

to exterior wall.

1. For vertical venting, where optional Concentric Vent

90° degree long radius elbow is attached to installed

Boiler Concentric Vent Collar, to install elbow:

a. Remove locking band clamp off the terminal and

set aside.

b. Lubricate the brown gasket inside boiler

concentric vent collar with small amount of

water.

CaUTiOn

c. Ensure that male end of the elbow inner plastic

pipe is evenly engaged into the gasket all around,

then, push the elbow male end inside boiler

concentric vent collar until the bead on male end

of elbow outer pipe bottoms out inside boiler

vent collar.

Exterior wall surface must be reasonably ﬂat to

attach the Outside Wall Plate. When exterior wall

surface is not ﬂat (covered with vinyl or wood

shingle siding etc.) the siding must be removed,

and a ﬂat surface build up ﬂash or above siding

exterior surface to secure/seal the terminal

Outside Wall Plate.

Figure 1ꢂ: Horizontal (Wall) Terminal Detail

i. 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.

Figure 18: Completing Horizontal (Wall)

Terminal installation

d. Re-install locking band clamp onto the joint to

secure the elbow to the collar.

j. Lubricate the brown gasket inside boiler

concentric vent collar or the last section of the

vent pipe with small amount of water.

e. Continue installing additional concentric vent

cuttable or non-cuttable piping as required.

k. 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 g) is no longer visible.

2. Additionally, secure elbow to boiler vent collar with

three evenly spaced #8 x ½” sheet metal screws.

Use collar rivets as reference attachment points.

Mark (center punch) each screw location off each

rivet centerline 5/8” towards collar-beaded end. See

Figure 18 ‘Completing Horizontal (Wall) Terminal

Installation’ for details. Drill 1/8” hole thru both

l. Re-install locking band clamp onto the joint

to secure the terminal to the collar or the last

section of the vent pipe.

2ꢀ

Figure 19: Vertical Concentric Vent installation

outer pipes to start the 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 sheet metal screws longer than ½”.

When Additional Concentric Vent Piping is

needed

1. If additional concentric vent piping is needed:

Figure 21: Fixed Extension (non-Cuttable)

a. Concentric Vent Cut-To-Length Extension pipes,

identiﬁed in Tables 8 and 10 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 20 ‘Cut-To-Length

Extension (Cuttable)”.

b. Remove the plastic inner pipe by pulling it out

from the female end.

c. 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. Deburr the cut end with a

ﬁle or emery cloth.

d. Make an insertion mark 1” from the male end of

the outer pipe.

e. 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 ﬁne tooth

hacksaw or a PvC saw to cut the plastic pipe and

be careful to cut the pipe square. Deburr the cut

edge of the plastic pipe with a ﬁle, razor blade or

ﬁne sandpaper.

Figure 20: Cut-To-Length Extension (Cuttable)

b. The remaining Concentric Vent Fixed Extensions

shown in Table 8 CANNOT BE CUT. These

pipes have beaded male and beaded female ends.

See Figure 21 ‘Fixed Extension (Non-Cuttable)’.

f. Reinstall the inner pipe.

2. To cut the Concentric Vent Straight pipe to required

length refer to Figure 22 “Cutting Straight Pipe” and

follow the procedure below:

3. To join Concentric Vent Pipe refer to Figure 23

“Joining Cuttable Pipe” and Figure 24 “Joining

Non-Cuttable Pipe” and follow the procedure below:

a. 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.

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

Lubricate the brown gasket in the boiler vent

collar with a few drops of water.

2ꢁ

Figure 22: Cutting Straight Pipe

b. Push the male end of the ﬁrst ﬁtting 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 2d above)

is covered. On other ﬁttings, the bead on the

male pipe will be bottom out on the collar (see

Figure 24).

c. The male end of cuttable ﬁttings 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 2ꢀ: Joining Cuttable Pipe

d. Use locking bands (provided with all ﬁttings) to

secure non-cuttable pipe, as well as ﬁttings, to

the boiler collar (see Figure 24).

e. Use the same method to join all remaining vent

components except for the terminal.

Vertical (Roof Terminal Installation

1. Vertical (Roof) Terminal Installation. Refer to

Figures 26, 27 and 28.

In addition to the vertical terminal, either a Flat

Roof Flashing or Sloped Roof Flashing is required

for this installation. Refer to Table 8 ‘Concentric

Vent Components’ for details.

Figure 2ꢁ: Joining non-Cuttable Pipe

abrasive wheel cutter. Be careful to cut the pipe

square. De-burr the cut end with a ﬁle or emery

cloth.

a. Determine the centerline of the terminal location

on the roof. For ﬂat roof, cut either 5-1/2”

diameter hole (80/125 mm concentric vent size)

or 6-1/2” diameter hole (100/150 mm concentric

vent size) 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.

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

beyond the end of the outer pipe (Figure 26).

Use a ﬁne 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 ﬁle or emery

cloth.

CaUTiOn

h. Make a mark on the terminal section 1” from the

cut end of the outer pipe as shown in Figure 26.

if the boiler is located directly under the hole,

cover it while cutting the hole to prevent debris

from falling onto boiler.

i. 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 3/8” into the outer

pipe. Do not use a sheet metal screw longer

than 1/2”.

b. Install the roof ﬂashing using standard practice

on the rooﬁng system of the structure.

c. 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

ﬂashing.

d. Measure distance “H” from the top edge of the

storm collar to the end of the last ﬁtting as shown

in Figure 25.

j. Secure the terminal section to the inside of

the roof structure using the mounting bracket

provided with the terminal (Figure 27).

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

length on the pipe as shown in Figure 26.

f. Cut the outer pipe only at the point marked in

Step (e) using aviation shears, a hacksaw, or an

Figure 25: Dimension "H"

Figure 26: Cutting Vertical Terminal

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.

Table 10: Cut-To-Length Extensions (Cuttable)

Part No.

Component Description

Size

Cut-To-Length Extension,

101163-01

500 mm (19-1/2”)

80/125 mm

Cut-To-Length Extension,

101162-01

101550-01

101551-01

1000 mm (39”)

Cut-To-Length Extension,

500 mm (19-1/2”)

100/150 mm

Cut-To-Length Extension,

1000 mm (39”)

Chimney Chase Installation.

b. Construct a weather-tight ﬂat roof to cover

the top of the old chimney. Install the vertical

terminal through this roof using the ﬂat roof

ﬂashing.

A vertical concentric vent system, either 80/125 mm

or 100/150 mm can be installed in an UNUSED

masonry chimney. Refer to Figure 28.

a. The Chimney chase Support Elbow with

attached Mounting Bracket is used at the base

of the chimney. Refer to Table 8 ‘Concentric

Figure 2ꢂ: Completing Vertical Terminal installation

2ꢂ

Figure 28: Chimney Chase installation

V. Condensate Disposal

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.

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 ﬂue gases in the boiler. The trap

has factory installed overﬂow switch, which shuts

down the boiler in the event the drain line becomes

obstructed, preventing proper condensate removal.

Refer to Section XIII “Service and Maintenance”

for condensate trap and condensate overﬂow switch

removal and replacement procedure, if required.

WaRning

Failure to install the condensate trap and

condensate drain in accordance with the above

instructions could cause ﬂue gas to enter the

building, resulting in personal injury or death.

3. Note the following when disposing of the

condensate:

CaUTiOn

a. Condensate is slightly acidic, typical pH around

3.5 - 4.5. Do not use metallic pipe or ﬁttings in

the condensate drain line. Do not route the drain

line through areas that could be damaged by

leaking condensate.

Boiler condensate is corrosive. Route

condensate drain line in a manner such

that any condensate leakage will not cause

property damage.

b. Do not route or terminate the condensate drain

Some jurisdictions may require that

condensate be neutralized prior to disposal.

line in arrears 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

furnaces. If overﬂow from the pump would

result in property damage, select a pump with an

overﬂow switch. Wire this switch in series with

installer provided external high limit, to shut off

the boiler, and, if desired, in series with installer-

supplied alarm, to trigger an alarm in the event

of overﬂow.

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.

d. Do not attempt to substitute another trap for one

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.

provided with the boiler.

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 and 1B.

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

5. Condensate trap must be ﬁlled up with water,

prior to boiler start-up and before connecting any

condensate line to the boiler, to insure combustion

products cannot escape from operating boiler. To ﬁll

the trap, inject water in the amount of 1 cup (8 ﬂuid

ounces) through condensate trap stub opening. Do

not overﬁll the trap.

condensate acidity before/after neutralizer thus

indicating a need for service and chip replacement.

ꢀ0

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 appliance operation and service (circulator replacement, etc.).

A. Installation of Factory Supplied Piping and Trim

nOTiCE

Components

Oxygen contamination of boiler water will cause

corrosion of iron and steel boiler components,

and can lead to boiler failure. Burnham’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.

Alpine (ALP) boilers have factory supplied

Miscellaneous Part Carton (P/N 101777-01 – ALP080

thru ALP210; 101777-02 – ALP285; 101777-03

– 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:

Do not ﬁll boiler with softened water to prevent

chloride contamination.

Figure ꢀ0: Factory Supplied Piping and Trim installation

ꢀ1

1. ALP080 thru ALP285 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. Mount the nipple into 1” boiler supply tapping

(see Figure 1A), 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.

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.

4. ALP285 Boiler Model

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

into the tee top outlet.

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.

d. Install Drain Valve into the tee bottom outlet.

2. ALP399 Boiler Model

b. Mount the nipple into 1¼” boiler supply tapping

(see Figure 1B), then, install the tee onto the

nipple, making sure ¾” branch outlet is in

horizontal plane and facing the boiler front.

a. Locate and remove (2) ¾” NPT x close black

nipples, 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 ¾” x ¼” NPT black reducing bushing

into the tee branch, then, put in Temperature &

Pressure Gauge.

5. ALP399 Boiler Model

c. Install the second close nipple into tee run top

outlet.

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.

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

into the tee top outlet.

e. Install Drain Valve into the tee bottom outlet.

b. Mount the nipple into 1½” boiler supply tapping

(see Figure 1B), then, install the tee onto the

nipple, making sure ¾” branch outlet is in

horizontal plane and facing the boiler front.

3. ALP080 thru ALP210 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.

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

into the tee branch, then, put in Temperature &

Pressure Gauge.

ꢀ2

B. Piping System To Be Employed.

nOTiCE

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 ﬂow through the

boiler remain within the limits shown in Table 11, any

time the boiler is ﬁring.

Failure to maintain the ﬂow through boiler within

speciﬁed 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

speciﬁed ﬂow range through boiler any time the

boiler is ﬁring:

Table 11: Flow Range Requirement Through Boiler

Required

Boiler

Supply

Boiler

Return

Minimum

Required Flow Head Loss,

(GPM)

@ 35°F DT

Boiler

Required

Flow,

(GPM)

Boiler

Head Loss,

Ft.

Boiler

Head Loss,

Maximum

Required

Boiler

Head Loss,

Ft. @ 25°F Flow (GPM) Ft.

Flow,

(GPM)

@ 25°F

Boiler

Model Connection, Connection,

Ft.

Inch, FPT

@ 35°F DT @ 30°F DT @ 30°F DT

@ 20°F DT @ 20°F DT

ALP080

ALP105

ALP150

ALP210

ALP285

ALP399

4.2

5.5

4.8

7.0

5.2

5.4

5.9

6.1

4.9

6.4

9.3

6.6

7.1

7.8

7.9

5.8

7.7

8.9

12.8

8.9

7.3

9.6

13.4

19.1

12.7

14.4

16.0

15.9

7.9

9.2

11.0

15.5

21.2

30.2

13.8

19.4

26.5

37.7

11.1

15.1

21.5

12.9

17.7

25.1

9.8

1¼

1½

1¼

1½

10.7

10.8

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

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

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

Alpine Boiler Head Loss vs. Flow

105

285

399

210

150

Flow Rate (GPM)

ꢀꢀ

a. The ﬂow rate through the isolated near-boiler

loop is maintained by factory recommended and

installer supplied boiler circulator.

compare the speciﬁed ﬂow range through an

Alpine model boiler to an indirect water heater

(Alliance SL™) model coil ﬂow rate required to

achieve water heater rating. Refer to Table 12B.

b. The ﬂow rate through the isolated near-boiler

loop is completely independent of the ﬂow rate

through the heating system loop(s).

f. When Alliance SL™ model coil ﬂow rate,

required to achieve water heater rating, falls

within the speciﬁed ﬂow range for Alpine

boiler model, the Alliance SL™ model can be

piped as part of Alpine near-boiler piping.

Refer to Table 12B, Figures 32A, 32B, 35 and 36

for recommended circulator models, piping and

wiring details.

c. The ﬂow 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 12A and

Figures 31A or 31B “Near Boiler Piping

- Heating Only” as applicable.

g. When Alliance SL™ model coil ﬂow rate,

required to achieve water heater rating,

exceeds the speciﬁed ﬂow 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 12B for

details.

ii. Space heating plus indirect water

heater(s) - refer to Tables 12A, 12B and, as

applicable, to:

• Figures 32A or 32B “Near Boiler Piping -

Heating Plus Indirect Water Heater”

- when indirect water heater can be piped

as part of near-boiler piping.

• Figures 32C or 32D “Near Boiler Piping -

Heating Plus Indirect Water Heater”

- when indirect water heater must be

piped as a separate heating zone off the

system header.

h. When Alliance SL™ model coil ﬂow rate,

required to achieve water heater rating, falls

below the speciﬁed ﬂow 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 ﬂow and combined

coil pressure drop and the zone piping total

equivalent length. Refer to Table 12B, Figures

32C, 32D, 37A and 37B for piping and wiring

details.

e. For installations where indirect domestic hot

water heater is combined with space heating,

when sizing an indirect water heater circulator,

Table 12a: Recommended Circulator Models for alpine (aLP) Boilers Based on 25°F Temperature Differential

and Up to 75 ft. Equivalent Length Near-Boiler Piping - Space Heating Circulator

Near-Boiler Near-Boiler

Piping Piping

Supply Pipe Return Pipe

Combined

Boiler & Piping

Loop Head

Loss, Ft.

Boiler Supply Boiler Return

Flow, GPM

@ 25°F Temp.

Differential

* Recommended

Circulator

Make & Model

Boiler

Model

Connection,

Inch, FPT

Size, Inch

Taco 0010

Grundfos UPS

15-58 FRC

ALP080

ALP105

ALP150

ALP210

ALP285

5.8

7.7

10.3

15.1

13.1

12.7

13.0

12.0

Taco 0014

Grundfos UPS

26-99 FC (second speed)

Taco 0014

Grundfos UP

26-99 FC (ﬁrst speed)

11.0

15.5

21.5

30.2

Taco 0014

Grundfos UP

26-99 FC (ﬁrst speed)

1¼

1½

1¼

1½

Taco 0013

Grundfos UP

26-99 FC (third speed)

1¼

1½

1¼

1½

Taco 1400-20

Grundfos UPS

ALP399

32-80/2 F (second speed)

notes:

* Circulator Models shown are not equipped with internal ﬂow 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.

ꢀꢁ

Table 13: Fitting and Valve Equivalent Length (cont’d)

Table 13: Fitting and Valve Equivalent Length

Copper Fitting and Sweat Valve Equivalent Length (Ft)

Threaded Fitting and Valve Equivalent Length (Ft)

Copper Pipe or Valve Size

Black Threaded Pipe or Valve Size

Fitting or Valve

Description

1¼

3.0

1½

4.0

1¼

1½

90° Elbow

2.5

1.0

0.5

4.5

23.5

0.3

25.0

5.3

4.3

4.5

54.0

2.7

90° Elbow

2.6

3.5

4.0

45° Elbow

1.2

1.5

Long Radius

Elbow (45° or 90°)

1.4

1.8

2.2

Tee (thru ﬂow)

0.6

0.8

Tee (thru ﬂow)

1.8

5.3

2.3

6.9

2.7

8.1

Tee (Branch ﬂow)

Diverter Tee (typical)

Gate Valve

5.5

7.0

Tee (Branch ﬂow)

25.0

0.4

23.0

0.5

Close Return

Bend

4.4

5.8

6.7

Globe Valve

36.0

7.8

46.0

9.4

Gate Valve (full open)

Globe Valve (full open)

Angle Valve (full open)

0.7

0.9

1.1

Angle Valve

30.0

13.0

39.0

17.0

46.0

20.0

Ball Valve (standard port)

Swing Check Valve

Flow-Check Valve (typical)

Butterﬂy Valve

7.0

6.6

5.5

6.5

Swing Check Valve

(full open)

8.7

12.0

60.0

13.0

63.0

74.0

2.0

57.0

2.7

Flow-Check Valve

(typical)

42.0

NOTE: Table 13 is provided as reference to assist in piping design and speciﬁes equivalent length of typical piping ﬁttings and

valves.

nOTiCE

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

waterways. Once ﬁlled 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, ﬂux and any residual boiler water additives. Flush the system thoroughly and

repeatedly,ifneeded,withclearwatermixedwithconcentratedrinseagenttoremovethesecontaminants

completely.

•

iron oxide (red oxide sludge Fe₂O_ꢀ) 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 reﬁll is not recommended, however, if such reﬁll is

employed, a water meter must be added to evaluate the makeup water volume taken after initial ﬁll 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 8.2 < pH < 9.5. if the system contains any aluminum components,

pH must be less than 8.5.

•

Black oxide sludge (magnetite Fe_ꢀO_ꢁ) 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 ꢀ to 9 grain/gal range.

•

Refer to Section Xiii “Service and Maintenance” for recommended heating system water treatment

products (corrosion/scale inhibitors, cleaners etc) and their suppliers.

ꢀꢂ

ꢀ8

ꢀ9

ꢁ0

ꢁ1

ꢁ2

ꢁꢀ

nOTiCE

WaRning

Where it is not possible to install a separate

boiler loop, the system circulator must be

sized to ensure that the ﬂow through boiler

stays within the deﬁned parameters to prevent

overheating when the boiler is ﬁred at it’s full

rated input. Install a ﬂow meter to measure the

ﬂow, or ﬁre the boiler at full rate and ensure the

boiler DT does not exceed ꢀ5°F.

Pressure 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 Section B above for

information on sizing the circulators.

2. Direct connection of Alpine (ALP) boiler to

heating system, similar to a conventional boiler, is

NOT RECOMMENDED because:

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.

a. The ﬂow rate through system must be the same

as through boiler and fall within limits speciﬁed

in Table 11.

b. Pressure drop through entire system must be

known, added to pressure drop through boiler,

and, a circulator selected to provide required

ﬂow at total calculated pressure drop.

4. Fill Valve (Required) – Either manual

(recommended) or automatic ﬁll valve may be used.

However, if automatic reﬁll is employed, a water

meter must be added to evaluate the makeup water

volume taken after initial ﬁll and eliminate any

water leakage as early as possible.

c. It is often very difﬁcult 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 ﬁttings in the

system. If system is zoned, the system ﬂow rate

may drop well below recommended minimum

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 ﬁll.

ﬂow when only a single zone is calling for heat.

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 36, 37A and

37B in VIII Electrical Section.

C. Piping Standard Installation Requirements.

Observe the following guidelines when making the

actual installation of the boiler piping:

1. Pressure Relief Valve (Required) - The relief valve

is packaged loose with boiler and must be installed

in the location shown in Figure 30 “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 shipped relief valve

is rated for 30 PSI maximum working pressure.

Optional 50 PSI maximum working pressure

rated relief valve is 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 ALP080 thru ALP285) or the

boiler I=B=R Gross Output rating (model ALP399).

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 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 ﬂoor. 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.

7. Flow Control Valve (Strongly Recommended)

- The ﬂow control valve prevents ﬂow through the

system unless the circulator is operating. Flow

control valves are used to prevent gravity circulation

or “ghost ﬂows” in circulator zone systems through

zones that are not calling for heat.

8. Isolation Valves (Strongly recommended) -

Isolation valves are useful when the boiler must be

drained, as they will eliminate having to drain and

reﬁll the entire system.

9. Drain Valve (Required) – Drain valve is packaged

loose with boiler and must be installed in the

location shown in Figure 30 “Factory Supplied

Piping and Trim Installation”.

10. Low Water Cutoff (Required by some Codes)

– LWCO with harness and LWCO transformer are

available as optional components. Order Complete

Kit (Part No. 102097-01) when required.

ꢁꢁ

a heat exchanger as shown in Figure 33. Consult

the heat exchanger manufacturer for proper heat

exchanger sizing as well as ﬂow 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.

D. Special Situation Piping 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:

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.

•

Radiant systems employing tubing without

oxygen barrier

3. Boiler Piping with Air Handlers - Where the

boiler is connected to air handlers through which

refrigerated air passes, use ﬂow control valves in the

boiler piping or other automatic means to prevent

gravity circulation during the cooling cycle.

•

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

Figure ꢀꢀ: isolation of the Boiler From Oxygenated Water with a Plate Heat Exchanger

ꢁ5

Vii. gas Piping

WaRning

3. Length of piping and number of ﬁttings. Refer

to Tables 14A (natural gas) or 14B (LP gas) for

maximum capacity of Schedule 40 pipe. Table 15

lists equivalent pipe length for standard ﬁttings.

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.

4. Speciﬁc gravity of gas. Gas piping systems for gas

with a speciﬁc gravity of 0.60 or less can be sized

directly from Tables 14A or 14B, unless authority

having jurisdiction speciﬁes a gravity factor be

applied. For speciﬁc gravity greater than 0.60,

apply gravity factor from Table 16. If exact speciﬁc

gravity is not shown choose next higher value.

an additional gas pressure regulator may be

needed. Consult gas supplier.

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

supply to boiler. Consider these factors:

For materials or conditions other than those listed

above, refer to National Fuel Gas Code, NFPA54/ANSI

Z223.1, or size system using standard engineering

methods acceptable to authority having jurisdiction.

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;

contact gas supplier for additional information.

Minimum gas valve inlet pressure is stamped on

the rating label located in the boiler’s vestibule

compartment.

B. Connect boiler gas valve to gas supply system.

WaRning

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).

Failure to use proper thread compounds on all

gas connectors may result in leaks of ﬂammable

gas.

Table 1ꢁa: Maximum Capacity of Schedule ꢁ0 Black Pipe in CFH* (natural gas) For gas Pressures

of 0.5 psig or Less

inlet Pressure 0.5 PSi or less; 0.ꢀ inch W.C. Pressure Drop

Nominal Pipe

Inside

Length of Pipe, Ft.

Size, In.

Diameter, In.

100

0.622

0.824

1.049

1.380

1.610

2.067

2.469

3.068

131

273

188

151

284

583

873

1681

2680

4738

129

243

499

747

1439

2294

4055

114

104

195

400

600

1156

1842

3256

514

353

215

442

662

1275

2033

3594

179

368

552

1063

1695

2996

167

343

514

989

1576

2787

157

322

482

928

1479

2615

148

304

455

877

1397

2470

1¼

1½

1056

1582

3046

4856

8584

726

1087

2094

3337

5900

2½

inlet Pressure 0.5 PSi or less; 0.5 inch W.C. Pressure Drop

Nominal Pipe

Inside

Length of Pipe, Ft.

Size, In.

Diameter, In.

172

100

0.622

0.824

1.049

1.380

1.610

2.067

2.469

3.068

118

360

247

199

170

320

657

985

1897

3024

5345

151

284

583

873

1681

2680

4738

137

257

528

791

1523

2428

4293

126

237

486

728

1402

2234

3949

117

110

104

195

400

600

1156

1842

3256

678

466

374

220

452

677

1304

2078

3674

207

424

635

1223

1950

3447

1¼

1½

1392

2085

4016

6401

11316

957

768

1433

2760

4400

7778

1151

2217

3533

6246

2½

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

value of your gas.

ꢁ6

Table 1ꢁB: Maximum Capacity of Schedule ꢁ0 Black Pipe in CFH* (LP gas) For gas Pressures

of 0.5 psig or Less

inlet Pressure 11.0 inch W.C.; 0.ꢀ inch W.C. Pressure Drop

Nominal Pipe

Inside

Length of Pipe, Ft.

Size, In.

Diameter, In.

100

0.622

0.824

1.049

1.380

1.610

2.067

2.469

3.068

184

126

238

488

732

1409

2246

3970

101

191

392

588

1131

1803

3188

346

163

336

503

968

1543

2729

145

297

446

858

1368

2418

131

269

404

778

1239

2191

121

248

371

715

1140

2016

112

231

346

666

1061

1875

105

216

324

624

995

1760

100

204

306

590

940

1662

1¼

1½

710

1064

2050

3267

5776

2½

inlet Pressure 11.0 inch W.C.; 0.5 inch W.C. Pressure Drop

Nominal Pipe

Inside

Length of Pipe, Ft.

Size, In.

Diameter, In.

100

0.622

0.824

1.049

1.380

1.610

2.067

2.469

3.068

116

242

166

314

644

964

1858

2961

5234

134

252

517

775

1492

2377

4203

114

101

191

392

588

1131

1803

3188

456

215

442

663

1277

2035

3597

173

355

532

1025

1634

2889

159

327

490

943

1503

2658

148

304

456

877

1399

2472

139

285

427

823

1312

2320

131

269

404

778

1239

2191

1¼

1½

937

1403

2703

4308

7615

2½

* 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 15: Equivalent Lengths of Standard Pipe Fittings & Valves

Valves (Screwed) - Fully Open

Screwed Fittings

Nominal

Pipe Size, Diameter,

Inside

180 Close

Return

Bend

90 Tee

Flow Thru

90 Tee,

Flow Thru

Branch

Swing

45°

90°

Gate Globe Angle

Inc.

In.

Check Elbow Elbow

Run

0.622

0.824

1.049

1.38

0.4

0.5

0.6

0.8

0.9

1.2

1.4

1.8

17.3

22.9

29.1

38.3

44.7

57.4

68.5

85.2

8.7

4.3

5.7

0.7

1.0

1.2

1.6

1.9

2.4

2.9

3.6

1.6

2.1

2.6

3.5

4.0

5.2

6.2

7.7

3.5

4.6

1.6

2.1

2.6

3.5

4.0

5.2

6.2

7.7

3.1

4.1

11.4

14.6

19.1

22.4

28.7

34.3

42.6

7.3

5.8

5.2

1¼

1½

9.6

7.7

6.9

1.61

11.2

14.4

17.1

21.3

9.0

8.0

2.067

2.469

3.068

11.5

13.7

17.1

10.3

12.3

15.3

2½

ꢁꢂ

Table 16: Speciﬁc Gravity Correction Factors

C. Pressure test. See Table 17 for Alpine Min./Max.

Pressure Ratings. The boiler and its gas connection

must be leak tested before placing boiler in operation.

Speciﬁc

Gravity

Correction

Factor

Speciﬁc

Gravity

Correction

Factor

0.60

0.65

0.70

0.75

0.80

0.85

1.00

0.96

0.93

0.90

0.87

0.81

0.90

1.00

1.10

1.20

1.30

1.40

0.82

0.78

0.74

0.71

0.68

0.66

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 non-

corrosive leak detector solution.

WaRning

DangER

gas supply to boiler and system must be

absolutely shut off prior to installing or servicing

boiler gas piping.

Do not use matches, candles, open ﬂames or

other ignition source to check for leaks.

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.

Table 1ꢂ: Min./Max. Pressure Ratings

Natural/LP

Gas

Max.

Pressure

(in. w.c.)

LP Gas

Min. Pressure

Inlet to Gas

Valve

Natural Gas

Min. Pressure

Inlet to Gas Valve

(in. w.c.)

Boiler

Model

No.

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

to action of liqueﬁed petroleum gas.

(in. w.c.)

3. Alpine (ALP) boilers have factory supplied

Miscellaneous Part Carton (P/N 101777-01

- ALP080 thru ALP210; 101777-02 - ALP285;

101777-03 - 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:

ALP080

ALP105

ALP150

ALP210

ALP285

ALP399

4.0

11.0

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

black nipple and ½” NPT external gas shutoff

valve (ALP080 thru ALP210), or ¾” NPT x

6” long black nipple and ¾” NPT external gas

shutoff valve (ALP285 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

identiﬁcation) 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 boiler gas

control valve and outside jacket. See Figure 34.

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.

Figure ꢀꢁ: Recommended gas Piping

ꢁ8

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.

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.

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

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

C. Refer to Figures 35 and 36 or details on the internal

boiler wiring.

1. Line Voltage (120 VAC) Connections (Figure 35)

– The line voltage connections are located in the

junction box on the left side of the vestibule:

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) located in the system

piping as shown in the Water Piping and Trim Section of this manual. Wire as indicated in the Electrical

Section of this manual.

nOTiCE

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

ꢁ9

•

Black – Line voltage “hot”

WaRning

White – “Neutral” for boiler and circulators

Red – “Heating” circulator “hot”

Blue – “Indirect Water Heater “ circulator “hot”

Green – Ground connection

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 (MCBa). One

example of an external power source that could

be inadvertently connected to the low voltage

connections is a transformer in old thermostat

wiring.

2. Maximum circulator continuous current draw is 2A.

With primary/secondary piping, it may be desirable

to use the boiler to directly control the primary

circulator in addition to the secondary circulator. If

this is done, control both heating circulators using

a relay with a 120VAC coil, such as a Honeywell

R4222, as shown in Figures 37A and 37B. Select a

relay with a contact rating in excess of the combined

draw of the two circulators.

4. If the outdoor sensor is connected to terminals 3

and 4, 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. In general, 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 ﬂuorescent 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.

3. Low Voltage Connections (Figure 35) – These

connections are screw terminals located on the

terminal strip next to the junction box on the left:

•

Terminals 1 and 8 – “Heating” thermostat

connections

Terminals 5 and 6 – “External Limit Control”

connections

Terminals 3 and 4 – “Outdoor Reset Sensor”

connections

Terminals 2 and 4 – “Domestic Indirect Water

Heater” thermostat connections

Terminal 7 – “Flame Signal Reading”

Heat anticipator setting for the thermostat

connection is 0.1 A when thermostat is connected

directly to terminals 1 and 8.

•

Figure ꢀ5: Wiring Connections Diagram

Figure ꢀ6: Ladder Diagram

Figure 37A: Modiﬁed Wiring For DHW Priority When Using Low Flow Circulator Piped Off System Header -

Heating (with Central Heating Circulators) Plus alternately Piped indirect Water Heater

5ꢀ

Figure 37B: Modiﬁed Wiring For DHW Priority When Using Low Flow Circulator Piped Off System Header -

Heating (with Central Heating zone Valves) Plus alternately Piped indirect Water Heater

5ꢁ

Figure ꢀ8: Wiring for MCBa Modulating Boiler Control Time Delay Relay Box

5. If the boiler installation site may be subject to low

f. Connect additional ﬁeld wiring (not included

in the kit) from MCBA Time Delay Relay Box

to 120 volt power wiring as per wiring diagram

(Figure 38).

supply voltage conditions or “brownouts”, that

would affect MCBA Modulating Boiler Control

operation, a separate optional Time Delay Relay

Box (P/N 101693-01) installation is strongly

recommended. See Figure 38 “Wiring for MCBA

Modulating Boiler Control Time Delay Relay Box”

and follow the following installation steps:

g. Install cover on MCBA Time Delay Relay Box

and restore power to boiler.

h. Measure time from when power is restored until

the boiler actually powers up (LED numbers

will reappear on MCBA display panel). This

MCBA Time Delay Relay Box has a delay on

make timer that delays powering of the boiler for

3 minutes whenever power is lost to the boiler.

Timing should be approximately 3 minutes, but

no longer than 4 minutes.

a. Turn off power to boiler.

b. Remove 120 volt power wiring, L1, L2 and

ground.

c. Remove cover to MCBA Time Delay Relay Box.

d. Mount MCBA Time Delay Relay Box on secure

surface near boiler.

i. Cycle boiler per installation manual.

e. Connect wiring to MCBA Time Delay Relay Box

as per wiring diagram (Figure 38).

iX. Boiler Stacking

For installations with unusually high space heating

and/or domestic hot water heating loads, where employing

two (2) Alpine (ALP) boilers will offer the beneﬁts of

greater operational efﬁciency, ﬂoor space savings and boiler

redundancy, the Alpine (ALP) boilers may be installed

stacked one on the top of the other. Refer to Table 18

“Alpine (ALP) Boiler Model Stacking Combinations” for

details.

bottom positioning dimples are evenly spaced

from boiler front and back, while side panel top

positioning dimples follow speciﬁc pattern to

compensate for Alpine (ALP) boiler model variable

depth.

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

boiler and align boiler front doors and sides ﬂush

with each other.

Table 18: alpine (aLP) Boiler Model

•

Place ﬁrst Stacking Boiler Attachment Bracket

onto the upper boiler left side panel, at the panel

lower left corner and align 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 veriﬁed, attach the bracket to top

and bottom boiler left side panels with the

mounting screws.

Stacking Combinations

Bottom Boiler Model

ALP080

Top Boiler Model

ALP080

ALP105

ALP080

ALP105

ALP150

ALP080

ALP105

ALP150

ALP210

ALP080

ALP105

ALP150

ALP285

ALP080

ALP105

ALP150

ALP210

ALP285

ALP399

ALP105

•

ALP150

ALP210

ALP285

5. Repeat above procedure to install second Stacking

Boiler Attachment Bracket and secure the stacked

boiler right side panels together at the front right

corner.

6. 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.

ALP399

7. Repeat above procedure to install the forth Stacking

Boiler Attachment Bracket to secure stacked boiler

right side panels at the rear right corner.

B. When installing stackable boiler combinations

A. To ﬁeld assemble individual Alpine (ALP) boilers

observe the following guidelines:

into a stackable conﬁguration, use the steps below:

1. Venting - Top and bottom boilers must have their

individual concentric vent piping and vent terminals.

1. Position the bottom boiler ﬁrst. Refer to Sections II

“Pre-Installation” and III “Unpacking Boiler” of the

manual for details. Always position higher input

boiler model as bottom boiler.

WaRning

no common manifolded venting is permitted.

2. 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 39

“Stacking Boiler Attachment Bracket Placement”.

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.

3. 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

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.

of an individual boiler. When common gas piping

is sized, insure it will have adequate capacity for

combined input (GPH gas ﬂow) of the selected

stackable boiler combination.

If vertical vent terminals cannot end in one plane,

they must be spaced no closer then three (3) feet

horizontally.

3. 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 for each individual boiler trim

installation.

Follow instructions in Section IV “Venting” of

the manual for speciﬁcs of individual boiler vent

termination. Follow instructions in Section V for

each individual boiler ﬂue gas condensate line

construction and condensate disposal. Terminating

individual boiler condensate lines into common

pipe prior to drain disposal is permissible, providing

common pipe has sufﬁcient ﬂow capacity to

handle combined condensate volume of stackable

combination.

4. Electrical - Follow instructions in Section VIII

“Electrical” of the manual to wire individual boilers.

Stackable boilers require a separate, installer

provided, staging control (Tekmar Model 265 or

equivalent) to operate the boilers. Follow control

manufacturer instructions to wire it to the boilers.

2. Gas Piping - Follow instructions in Section VII “Gas

Piping” of the manual for sizing and installation

Figure ꢀ9: Stacking Boiler attachment Bracket Placement

5ꢂ

X. Modular installation

Using PVC Pipe for Individual Module Combustion

Air Intake Piping – (See Figure 40)

A. General Guidelines

1. Read and follow all venting, combustion air,

water piping, gas piping and electrical instructions

contained in the Installation, Operating and Service

Instructions unless otherwise instructed in this

section.

1. Each individual module (boiler) must have own

combustion air intake pipe and combustion air

intake terminal. Refer to Section IV “Venting” of

these Instructions for individual module (boiler)

combustion air intake guidelines and options.

2. Consult Local Building Codes or National Fuel Gas

Code, NFPA 54/ANSI Z222.3 for restrictions and

instructions on modular boiler installations.

2. The individual module (boiler) maximum

combustion air intake pipe length is sixty (60)

equivalent feet.

B. Modular Boiler Venting System Arrangements

3. If possible, locate each individual module (boiler)

both combustion air intake termination and vent

termination on the same side wall, to prevent

nuisance boiler shutdowns.

Using CPVC/PVC pipe for Individual Module Vent

Piping – (See Figure 40)

1. Each individual module (boiler) must have own

vent pipe and vent terminal. Refer to Section IV

“Venting” of these Instructions for individual

module (boiler) venting guidelines and options.

However, if same side wall placement is

problematic, an individual module (boiler) may

be installed using vertical venting and side wall

combustion air intake termination (or, vice versa)

WaRning

Using Concentric Combination Venting/Combustion

Air Intake Piping - Inner Polypropylene Vent

Pipe/Outer Combustion Air Intake Steel Pipe Casing

– (See Figure 40)

no common manifolded venting (vent piping and

vent terminals) is permitted.

2. The individual module (boiler) maximum vent

length is sixty (60) equivalent feet.

1. Each individual module (boiler) must have own

concentric vent pipe and vent termination. Follow

Section IV “Venting” of these Instructions for

individual module (boiler) concentric venting

guidelines.

3. For side wall 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.

WaRning

no common manifolded concentric venting is

permitted.

2. The individual module (boiler) maximum concentric

vent length is sixty (60) equivalent feet.

CaUTiOn

3. 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.

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.

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.

4. Individual module (boiler) sidewall vent terminals

must be placed at least twelve (12) inches above the

ground plus the expected snow accumulation.

4. Individual module (boiler) sidewall concentric

vent terminals must be placed at least twelve (12)

inches above the ground plus the expected snow

accumulation.

5. Multiple individual module vertical vent pipes may

be piped through a common conduit or chase so that

one roof penetration may be made.

5. 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.

The minimum horizontal distance between any

adjacent individual module (boiler) roof vent

terminations is one (1) foot.

If vertical vent terminals cannot end in one plane,

they must be spaced no closer than three (3) feet

horizontally.

D. Modular Boiler Gas Piping

1. Individual module (boiler) gas pipe sizing speciﬁc

details

6. 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.

2. Individual module (boiler) recommended gas piping.

See Figure 34.

3. Requirement to install additional gas pressure

regulators to properly regulate gas pressure at the

input of the smallest individual module (boiler).

If vertical vent terminals cannot end in one plane,

they must be spaced no closer then three (3) feet

horizontally.

WaRning

7. When individual modules (boilers) are installed in

the same horizontal plane, chimney chase vertical

concentric venting is permitted provided:

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.

a. Sufﬁcient inside space available at the base of

the chimney to install multiple chimney chase

brackets and support elbows.

b. Spacing between adjacent vertical vent terminals

is in accordance with paragraph 6 above.

CaUTiOn

E. Modular Boiler Electrical

installing multiple individual module (boiler)

concentric vent terminations too close together

may result in combustion product water vapor

condensation on building surfaces, where

termination are placed, and subsequent frost

damage. To avoid/minimize frost damage extend

the distance from building surfaces to concentric

vent termination end as well as increase the

horizontal distance between adjacent concentric

vent terminations.

Refer to Section VIII “Electrical” of these Instructions

for:

1. Individual module (boiler) wiring speciﬁc details

2. Individual module (boiler) internal wiring details,

high and low voltage connections

Each individual module (boiler) must be provided with own

fused disconnect and own service switch.

Installmodularboilerwiringinaccordancewithrequirementsof

authorityhavingjurisdiction. Inabsenceofsuchrequirements,

followtheNationalElectricCode, NFPA70and/orCSAC22.1

Electric Code.

C. Modular Boiler Water Piping – (See Table 19 and

Figure 42)

Refer to Section VI “Water Piping and Trim” of these

Instructions for:

F. Modular Boiler Control Systems – (See Figures 44

and 45)

1. Installation of Factory Supplied Piping and Trim

Components for an individual module (boiler).

1. Follow modular boiler control system manufacturer

(Honeywell, Tekmar etc.) instructions to properly

apply a modular control system.

2. Regarding an individual module (boiler) piping

system speciﬁc details.

2. Tekmar model 264 and model 265 based control

wiring diagrams (Figures 44 and 45) are provided as

examples of typical modular boiler control system.

3. Selection criteria for individual module (boiler)

space heating and/or DHW circulators.

3. Additionally, common modular boiler control

systems may use outdoor temperature sensing,

return water temperature sensing or both to stage

modular boilers.

Table 19: Modular Boiler Water Manifold Sizing

number of Units

Boiler Model

ꢀ

ꢁ

ꢂ

Recommended Minimum Common Water Manifold Size (nPT)

aLP080

aLP105

aLP150

aLP210

aLP285

aLPꢀ99

1¼”

1½”

2”

1½”

2”

2½”

ꢀ”

2½”

ꢀ½”

ꢁ”

2½”

ꢀ”

2½”

ꢀ”

2”

2½”

ꢀ”

ꢀ½”

ꢁ”

2”

2½”

ꢀ”

ꢁ”

2½”

ꢀ”

ꢀ½”

ꢁ”

5”

ꢀ”

5”

6ꢀ

6ꢁ

Xi. System Start-up

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

electrical system are installed properly. Refer to

installation instructions contained in this manual.

nOTiCE

If it is required to perform a long term pressure

test of the hydronic system, the boiler should

ﬁrst be isolated to avoid a pressure loss due to

the escape of air trapped in the boiler.

B. Conﬁrm all electrical, water and gas supplies are

turned off at the source and that vent is clear of

obstructions.

To perform a long term pressure test including

the boiler, ALL trapped air must ﬁrst be removed

from the boiler.

C. Conﬁrm that all manual shut-off gas valves between

the boiler and gas source are closed.

a loss of pressure during such a test, with no

visible water leakage, is an indication that the

boiler contained trapped air.

WaRning

Completely read, understand and follow all

instructions in this manual before attempting

start up.

3. Temporarily turn off all other gas-ﬁred appliances.

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

D. If not already done, ﬂush the system to remove

sediment, ﬂux 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:

5. Open the ﬁeld installed manual gas shut-off valve

located upstream of the gas valve on the boiler.

6. Conﬁrm that the supply pressure to the gas valve is

14 in. w.c. or less. Refer to Table 21 for minimum

supply pressure.

nOTiCE

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.

pH between 8.2 and 9.5.

if system contains aluminum components, pH

must be less than 8.5

Total Dissolved Solids - less than 2500 PPM

Hardness - ꢀ to 9 grains/gallon.

DangER

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

the system.

Do not use matches, candles, open ﬂames or

other ignition source to check for leaks.

WaRning

8. Purge gas line of air.

G. Operating Instructions

The maximum operating pressure of this boiler

is ꢀ0 psig. never exceed this pressure. Do not

plug or change pressure relief valve.

Start the boiler using the lighting instructions, see

Figure 46. After the boiler is powered up, it should go

through the following sequence.

E. Conﬁrm that the boiler and system have no water

Sequence

Display

Meaning

leaks.

U.125

or Blank

Checking internal software

(power-up only)

F. Prepare to check operation.

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

from gas supplier.

0.SWT

Boiler in standby. SWT = Supply

Water Temp. No call for heat.

(After call for heat from heating

thermostat)

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.

A.SWT

5.SWT

Self-Check on Start-up

Blower and circulator on. Check-

ing for adequate air ﬂow.

1.SWT

2.SWT

3.SWT

Prepurge

Trial for ignition

Flame established. Boiler re-

sponding to a call for heat.

Alpine™ Series Lighting and Operating Instructions

Figure ꢁ6: Lighting instructions

6ꢂ

Figure ꢁꢂ: Burner Flame

H. Purge Air From Gas Train

K. Perform Combustion Test

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

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

it may take several tries for ignition before a ﬂame 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 ﬂame has been established for the

ﬁrst time, subsequent calls for burner operation should

result in a ﬂame on the ﬁrst try.

Perform a combustion test. Boilers equipped with a

concentric vent system have a ﬂue gas sample tap

located in the boiler vent collar (under the screw cap).

Insert the analyzer probe in the ﬂue gas sample tap.

Check CO₂(or O₂) and CO at both high and low ﬁre.

The boiler may be temporarily locked into high or low

ﬁre for 15 minutes as follows:

1. To lock the boiler in high ﬁre, simultaneously press

and hold the “Mode” button and “+“ button until the

display ﬂashes “H”, indicating that the boiler has

been driven to high ﬁre. After this happens, allow

the boiler to operate for approximately 5 minutes

before taking combustion readings.

I. Check Burner Flame

Inspect the ﬂame visible through the window. On high

ﬁre the ﬂame should be stable and mostly blue (Figure

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

intermittent ﬂecks of yellow and orange in the ﬂame are

normal.

2. To lock the boiler in low ﬁre, simultaneously press

and hold the “Mode” button and “-“ button until the

display ﬂashes “L”, indicating that the boiler has

been driven to low ﬁre. After this happens, allow the

boiler to operate for approximately 5 minutes before

taking combustion readings.

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.

3. Normal modulation of the boiler should return 15

minutes after the boiler is locked in high or low ﬁre.

WaRning

Typical CO₂readings are shown in Table 20.

The outlet pressure for the gas valve has been

factory set and requires no ﬁeld 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.

WaRning

Each alpine Series boiler is tested at the factory

and adjustments to the air fuel mixture are

normally not necessary. Consult a U.S. Boiler

representative before attempting to make any

such adjustments. improper gas valve or mixture

adjustments could result in property damage,

personal injury, or loss of life.

Table 20: Recommended Combustion Settings,

natural gas

Altitude Range

Boiler

Model

0 - 7000 Ft.

L. Test External Limits

% CO₂

% O₂Range

CO, PPM

Test any external limits or other controls in accordance

with the manufacturer’s instructions.

ALP080

ALP105

ALP150

ALP210

ALP285

ALP399

M. Check Thermostat Operation

Less than 75

PPM

8.2 - 8.8

5.5 - 6.5

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.

Table 21: Permitted Conversions

N. Adjust Supply Water Temperature

As shipped, the heating and indirect water heater set

point supply temperatures are both set to 180°F. If

necessary, adjust these to the appropriate settings for

the type of system to which this boiler is connected. See

Section XII “Operation” of this manual for information

on how to do this.

Gas

Valve

Planned

Installation

Altitude

Fuel Converted

Boiler

Model

(Dungs)

Size Gas Valve Model

(NPT)

From

Range

GB-WND 055 D01

ALP080

S00 253082

ALP105

ALP150

GB-WND 055 D01

1/2”

O. Adjust Thermostats

S00 253083

Natural

Gas

Adjust the heating and indirect water heater thermostats

to their ﬁnal set points.

GB-WND 055 D01

0 - 7,000 Ft.

ALP210

ALP285

ALP399

S00 253084

GB-WND 057 D01

P. Field Conversion From Natural Gas to LP Gas

S00 253085

3/4”

GB-WND 057 D01

Alpine Series boilers are factory shipped as Natural Gas

builds. Follow steps below for ﬁeld conversion from

Natural Gas to LP Gas.

S00 253086

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.

WaRning

This conversion should be performed by a

qualiﬁed service agency in accordance with the

manufacturer’s instructions and all applicable

codes and requirements of the authority having

jurisdiction. iftheinformationintheseinstructions

is not followed exactly, a ﬁre, an explosion or

production of carbon monoxide may result

causing property damage, personal injury, or loss

of life. The qualiﬁed service agency is responsible

for proper conversion of these boilers. The

conversion is not proper and complete until the

operation of the converted appliance is checked

as speciﬁed in the Alpine™ Installation, Operating

and Service instructions.

4. Before attempting to start the boiler, make the

number of turns to the throttle screw called for in

Table 22.

Table 22: number of Clockwise Throttle Screw

Turns

Throttle Screw Turns at

Altitude Range

Boiler Model

Gas Valve

0 - 7000 Ft.

ALP080

ALP105

ALP150

ALP210

2¾

Dungs

GB-055

(½” NPT)

WaRning

3¼

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 ﬂue gas. Adjusting the

air-fuel mixture without a proper combustion

analyzercouldresultin unreliableboileroperation,

personal injury, or death due to carbon monoxide

poisoning.

Dungs

GB-057

(¾” NPT)

ALP285

ALP399

4½

1¾

Dungs

GB-057 HO

(¾” NPT)

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 ﬁrst

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.

1. Make sure that the planned fuel conversion is listed

in Table 21. If the planned conversion is not shown

in Table 21, it is not permitted. Refer to Figure

34 to identify the valve used on the model being

converted.

2. Conversion of Alpine Series boilers from one fuel

to another is accomplished using the throttle screw

on the gas valve. Figure 48 shows the location of

the throttle screw on the Dungs valve. Locate the

throttle on the boiler being converted.

7. Perform a combustion test. Boilers equipped with a

concentric vent system have a ﬂue gas sample tap

located in the boiler vent collar (under the screw

cap).

8. While the burner is at high ﬁre adjust the throttle as

needed to obtain the CO₂(or O₂) settings shown in

the Table 23:

•

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

CO₂range shown in this table.

Table 2ꢀ: Recommended Combustion Settings,

LP gas

Altitude Range

Boiler

Model

0 - 7000 Ft.

% CO₂

% O₂Range

CO, PPM

ALP080

ALP105

ALP150

ALP210

ALP285

ALP399

Less than

75 PPM

9.5 - 10.1

5.5 - 6.5

9. 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:

Figure ꢁ8: Dungs gas Valve Detail

6. After the burner lights, force the burner to high ﬁre

by simultaneously pressing and holding the “Mode”

button and “+“ button. After a few seconds, the

display should ﬂash “H”, indicating that the boiler

has been driven to high ﬁre. Allow the boiler to

operate for approximately 5 minutes before taking

combustion readings. Note: after 15 minutes, the

boiler is automatically released from high ﬁre hold.

Be sure to restore high ﬁre hold if additional time is

needed to obtain high ﬁre combustion readings.

10. A label sheet is provided with the boiler for

conversions from natural to LP gas. 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.

WaRning

The pressure regulator has been factory set using precision instruments and must never be adjusted in

the ﬁeld. 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 will result in damage to the gas valve and may cause property damage, personal injury or loss of

life.

ꢂ0

WaRning

The throttle adjustments shown in Table 22 are approximate. The ﬁnal 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 2ꢀ 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 deﬁciency.

at 0% Excess air the CO₂readings will be either 11.9% CO₂for natural gas or 1ꢀ.8% CO₂for LP gas (O₂will

be 0%) and CO level will be extremely high (well over 1000 PPM).

If the burner operates with air deﬁciency, the following phenomena may be observed:

% CO₂will actually drop (% O₂will increase) as the throttle is turned counterclockwise

% CO₂will actually increase (% O₂will drop) as the throttle is turned clockwise

If the boiler appears to operate with air deﬁciency, turn the throttle clockwise to increase the amount of

Excess air to the burner.

as the throttle is turned clockwise, the CO₂level will rise, eventually peaking @ 11.8% or 1ꢀ.8%, depending

of the type of gas being used, before falling (conversely, O₂level will drop to 0% before rising). after this

happens, continue turning the throttle clockwise, until CO₂level drops (or O₂level increases) to the values

shown in Table 20 or Table 2ꢀ.

Table 2ꢁ: inlet Pressure Limits

•

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.

Inlet Pressure (Inches w.c.)

Fuel

Min.

4.0

Max.

14.0

Natural Gas

11.0

11. Refer to Section XI “System Start-up” of this manual

and perform any checks not already completed.

ꢂ1

Xii. Operation

c. “Stby” for Standby Mode. Upon entering

standby mode, “Stby” will brieﬂy appear on

the display and then the display will show the

boiler’s status along with the supply temperature

(Figure 49).

I. Factory Preset Boiler Operating Parameters

(See Table 25 for Parameter Descriptions)

A. The Alpine (ALP) boiler uses a microprocessor based

Honeywell control, known as a “MCBA”, to manage

all boiler functions including ﬂame supervision and

modulation. Two set point or “target” boiler supply

temperatures are stored in the MCBA’s memory;

one for space heating and one for domestic water

production. If an outdoor temperature sensor is

connected to the boiler, the space heating supply set

point will automatically adjust downwards as the

outdoor temperature increases. For more information

on this feature see the discussion on boiler water reset

below.

The control will return to standby mode from any

other mode if no key is pressed for 20 minutes.

The MCBA modulates the boiler input by varying the

fan speed. As the fan speed increases, so does the

amount of gas drawn into the blower. As a result, a

fairly constant air-fuel ratio is maintained across all

inputs.

Figure ꢁ9: normal Display in Standby Mode

C. In standby mode, it is possible to view both the

heating supply set point temperature and the “domestic

hot water reference set point”. The “domestic hot

water reference set point” plus 45°F equals the boiler

supply set point when it is responding to a call from

the indirect water zone. It is not the actual domestic

hot water set point. The Alpine (ALP) is designed

for use with a storage type indirect water heater such

as the Alliance SL™. The domestic water set point

is controlled by the thermostat on the indirect water

heater. The “default domestic water reference set point”

is 135°F and target boiler supply temperature when

responding to a call from the indirect water heater is

therefore 180°F (135°F +45°F). The default heating

supply set point (parameter 4) is 180°F.

The MCBA determines the input needed by looking

at both current and recent differences between the

supply temperature and the set point temperature.

As the supply temperature approaches the set point

temperature, the fan will slow down and the input drop.

Depending on the model boiler, the minimum input

is between 1/3 (high altitude) and 1/5 (sea level) of

maximum input.

The MCBA also monitors boiler return and ﬂue

temperatures. In addition, all other safety controls,

including the low water cut-off and safety limit, are

connected into the MCBA. The MCBA uses input from

all of these controls to either shut down the boiler when

an unsafe condition exists or, in some cases, to correct

the problem.

In standby mode it is also possible to turn on or off

either the heating or domestic water zone. There is

normally no reason to turn off either of these zones and

doing so is not recommended.

B. The display panel has three primary modes of

operation. These are:

WaRning

1. Standby Mode – Displays boiler’s current status.

This is the default operating mode.

Pushing and holding the “+” while in Standby

Mode will prevent the boiler from responding to

a call for heat. Pushing and holding the “-” while

in Standby Mode will prevent the boiler from

responding to a call for domestic water. if this

happens, “cOFF” or “dOFF” will appear on the

display. To turn back on the heating function,

press and hold “+” until “c” and the set point

temperature appears on the display. To turn back

on the domestic water function, press and hold “-”

until “d” and the set point temperature appears on

the display. after pressing any keys, and before

leaving the installation, verify that the boiler ﬁres

in response to a call for heat and domestic water.

2. Parameter Mode – Used to change control settings

3. Information Mode – Displays boiler operating

temperatures

Under normal conditions, the boiler is in standby mode

and the display looks like that shown in Figure 49. The

three digits to the right of the decimal point are the

boiler’s supply temperature. The digit to the left of the

decimal point is the boiler’s status code. A list of status

codes, and their meanings, is shown in Table 26.

Figure 50 is a map of the menu structure for the control

panel. Push the mode key to move from one mode

to the next. As you change modes, the mode you are

entering is shown on the display:

a. “PArA” for Parameter Mode

b. “Info” for Information Mode

ꢂ2

Table 25: Parameter Descriptions

Factory Setting

Access Parameter

Description

Code

No.

ALP080 ALP105 ALP150 ALP210

ALP285 ALP399

T3set DHW

DHW system

CH system

140

1 (On)

190

130

access

Code

needed

T1top CH Mode

T1foot CH Mode

T4 minimum

T4 maximum

T4 frost protection *

-22

T4 correction

Tblocking

Booster time

Tparallel shift

13/14

15/16

17/18

Maximum fanspeed CH

Maximum fanspeed DHW

Minimum fanspeed

4450

1125

4850

1250

5500

1300

3000

6200

1375

6300

1450

5867

1267

2300

Ignition fanspeed

CH postpump time

10.2

DHW postpump time

CH modulation hysteresis on

CH modulation hysteresis off

DHW modulation hysteresis on

DHW modulation hysteresis off

DHW detection hysteresis on

DHW detection hysteresis off

CH blocking time

-8

DHW blocking time

DHW-> CH blocking time

Modulate back difference T1-T2

RMCI Address

-1

Tplus: Setvalue addition for DHW

2nd CH-Circuit (1st digit)

CH Type (2nd digit)

34-1

34-2

35-1

35-2

0 (2nd Heating Circuit Off)

0 (Room Thermostat)

DHW 3=way valve or pump (1st digit)

DHW-type (2nd digit)

Manual fanspeed

1 (Hot Water Pump)

3 (Storage Tank without NTC3)

-1

37-1

37-2

PWM-pump level (1st digit)

PWM-pump level (2nd digit)

Tset hold boiler warm

Ttop for 2nd CH circuit

Tfoot for 2nd CH circuit

Thysteresis for 2nd CH circuit

Pump settings for CH and DHW

Minimum Off Cycle (2nd digit)

190

130

42-1

42-2

0 (CH Normal Pump)

0 (Not Active)

* Circulator will start when boiler supply sensor will detect temperature 44.6° F or less

ꢂꢀ

ꢂꢁ

D. Two basic types of errors codes are shown on the

G. An external limit control can be installed between

terminals 5 and 6 on the terminal strip. Be sure to

remove the jumper between terminals 5 and 6 when

adding an external limit control to the system. If the

external limit opens, the boiler will shut down and error

code “b 26” will be displayed. If the limit installed is

a manual reset type, it will need to be reset before the

boiler will operate.

display:

1. Soft Lockout Codes – When a soft lockout occurs,

the boiler will shut down and the display will

alternate between the number “9” and the letter

“b” followed by a two digit service code. A list of

these codes, and their meanings, is shown in Table

29 in Section XIV Troubleshooting. The boiler will

automatically restart once the condition that caused

the lockout is corrected.

H. The sequence of operation for a Alpine Series boiler

on a call for heat from a thermostat is as described

below:

2. Hard Lockout Codes – When a hard lockout occurs,

the boiler will shut down and the display will ﬂash

the letter “E” followed by a two digit service code.

A list of these codes, and their meanings, is shown

in Table 30 in Section XIV Troubleshooting. Once

the condition that caused the lockout is corrected,

the boiler will need to be manually reset using the

RESET button on the display.

1. When power is ﬁrst turned on, 120V is provided

to the MCBA, the combustion fan and the LWCO

transformer. A separate 50VA transformer,

connected directly to the MCBA, powers all other

low voltage circuits.

2. For the ﬁrst few seconds after power-up the control

module goes through a self check.

Table 2ꢀ: Boiler Status

3. When there is a call for heat, the control module

checks to make sure the air pressure switch is

open. If it is, the combustion fan will be energized

and will ramp up to ignition speed. When the air

pressure switch closes, a 10 second prepurge is

activated.

First

Boiler Status

Digit

Burner off - No call for heat or DHW

Pre-purge or post-purge

Ignition

4. After the prepurge, the control module energizes

the gas control valve and the spark for 4.5 seconds.

If a ﬂame is established and proved, the control

allows the ﬂame to stabilize for 5 seconds at the

combustion fan ignition speed setting. If the ﬂame

fails to prove, the control module will attempt to

light the burner 4 more times. If a ﬂame is still not

established, the control will lockout.

Burner responding to call for heat

Burner responding to call for DHW

Checking air pressure switch

Burner off - Set point temperature has been reached

Call for heat ended. 10s heating post pump period

Call for DHW ended. 10s DHW post pump period

9 and b Burner off - on soft lockout. See Troubleshooting Section to

Flashing determine meaning of error code.

5. Once the ﬂame stabilization period has ended,

the MCBA allows the burner to modulate. The

actual ﬁring rate is dependent upon the measured

current and recent differences between the set point

temperature and the supply temperature. If an

outdoor sensor is connected to the control module

and the boiler is responding to a call for heat, the set

point temperature will be determined by the outdoor

reset curve shown in Figure 51.

Boiler responding to call from heating zone

Burner on - Held in high ﬁre

Burner on - Held in low ﬁre

E. If an outdoor sensor is installed, the boiler will

automatically adjust the heating zone set point

temperature based on the outdoor reset curve in Figure

51. The maximum set point is deﬁned by parameter

4 (factory set to 180°F) when the outdoor temperature

is 0°F or below. The minimum set point temperature

shown is 100°F when the outdoor temperature is 60°F

or above. As the outdoor temperature falls the supply

water target temperature increases. For example,

if the outdoor air temperature is 30°F, the set point

temperature for the supply water is 140°F.

6. Once the set point temperature is reached, the

MCBA will turn the burner off and allow the

combustion fan to operate in postpurge for 30

seconds before it turns off.

7. The central heating pump will continue to operate

until the room thermostat has been satisﬁed.

8. A demand for domestic hot water (DHW) is given

priority on Alpine Series boilers. If a call for DHW

is received while the boiler is responding to a call

for heat, the heating circulator is de-energized until

the call for DHW is satisﬁed.

F. An indirect water heater thermostat can be connected

between terminals 2 and 4 on the terminal strip. When

this thermostat closes, the central heating circulator will

be turned off and the DHW circulator will be turned on.

ꢂ5

Additionally, either the keypad or the personal computer can

be used to obtain information about the boiler current status

and operating history.

A. Adjusting Parameters via Boiler Keypad

Entering the Access Code

1. With boiler running, toggle the Mode key until you

reach the (STBY) Standby mode.

2. Depress and hold the Step key and then quickly

depress and hold the Mode key for 2 - 6 seconds

until the display reads (CODE). Release the Mode

key, then the Step key. The display should show a

‘C’ followed by a random two digit number.

3. Use the + or - keys to scroll to the number 05.

4. Press the Store key momentarily and watch for the

display to blink twice. If the access code has been

successfully entered, the menu tree will be expanded

to include the items shown inside the dashed lines

in Figure 52. Access to parameters 5 - 42 will be

possible by following the instructions in Section

C. After 15 minutes have passed without any keys

being pressed, access to the expanded menu will

end and the access code will need to be reentered to

regain access to parameters 5 - 42.

Figure 51: Outdoor Reset Curve

II. Field Adjustable Boiler Operating

Parameters

MCBA control factory programmed operating parameters

will result in satisfactory operation under most conditions.

However, because all systems are different, there may exist

situations where boiler operation may be enhanced by

adjusting a few of these parameters in the ﬁeld. A total of

46 ﬁeld adjustable parameters are stored in the memory

of the MCBA control. By adjusting these parameters an

installer can ﬁne-tune MCBA operation under different

ﬁelds conditions. Refer to Table 25 for the list of adjustable

parameters and their factory settings.

NOTE: Access Code is not required for Parameters 1

thru 4.

Changing Parameters

1. Toggle the Mode key until you reach (PARA)

Parameter mode.

2. Press the Step key to scroll through the parameters

until you reach the desired parameter number.

3. Use the + or - key to scroll to the desired parameter

setting.

Parameters are numbered from “1” to “42-2”. Parameters

“1” thru “4” are accessible by anyone. Parameters “5” thru

“42-2” require an access code to be viewed and adjusted.

4. Press the Store key momentarily and watch for the

display to blink once. The parameter setting has

now stored it new value.

Parameters may be changed by:

•

Using the keypad on the boiler as input device to

make adjustments.

5. When using the keypad, all parameters show up on

the boiler display as two-digit numbers. This creates

the following special situations:

•

Using personal computer, hooked up to MCBA

control via the GPI PC Interface Kit (P/N 101152-

01), available from US Boiler, as input device to

make adjustments.

a. Two parameters are required to deﬁne some

of the fan speeds. For example, the maximum

CH fan speed is deﬁned by Parameters 13 and

WaRning

improper setting of parameters can cause unreliable or unsafe operation, resulting in property damage,

personal injury, or loss of life:

•

Changing parameters should only be attempted by a professional heating service technician.

•

Do not change any parameters not described in this manual without first consulting the

manufacturer.

After changing any parameters, carefully conﬁrm proper boiler operation before leaving the installation

site.

ꢂ6

Figure 52: Expanded Menu Tree (Cont’d on next page)

ꢂꢂ

Figure 52: Expanded Menu Tree (cont’d.)

Figure 5ꢀ: adjusting Boiler Water Reset Curve

ꢂ8

14; Parameter 13 deﬁnes the “thousands” and

hundreds” places and Parameter 14 deﬁnes the

“tens” and “ones” places. The ignition fan speed

is only adjustable in increments of hundreds, so

only one parameter (19) is required to deﬁne it.

the target supply temperature is always deﬁned

by Parameter 4 when the boiler is responding to

a call for central heat, regardless of the outdoor

temperature. In this case, the settings of Parameters

5, 6, and 7 are meaningless.

IMPORTANT: Field adjustment of fan speeds is

not recommended.

3. Allowing an external control to directly manage

modulation of the boiler. The MCBA control

permits the Alpine to be modulated solely using 0 -

10 VDC signal supplied by an external control,

like multiple - modulating boiler control. When this

function is used, the boiler no longer responds to a

heating thermostat, or an outdoor sensor connected

to a boiler MCBA itself. The boiler will respond

normally to the call from the domestic hot water

thermostat.

b. In some cases one two-digit number deﬁnes two

separate parameters. For example, if Parameter

34 is viewed on the boiler display, the “tens

place” is Parameter 34-1 (default value is 0) and

the “ones place” is Parameter 34-2 (default value

is also 0). As viewed on the boiler display, the

factory set Parameter 34 will therefore appear as

“00”. If Parameters 34-2 is changed to accept a

0-10 VDC reading from an AM-4 (see Section

D), Parameter 34 will then read “04” as viewed

on the boiler display.

In order for the boiler MCBA control to

recognize 0 - 10 VDC signal, Parameter 34-2

(“Room Thermostat” - see Table 25) must be

re-programmed. The factory programmed

default value for Parameter 34 is “0”. It must

be re-programmed to value “4” for MCBA to

recognize 0 - 10 VDC signal. Once this parameter

is changed, the boiler will ignore any call from a

thermostat connected across boiler terminals 1 and 2

(see Figures 35 and 36). It will continue to respond

to a call from the indirect water heater thermostat.

Common Field Adjustments

Please note that although it is physically possible to

adjust all parameters listed in Table 25 the parameters

shaded gray need not be adjusted in the ﬁeld. In case

these parameters are accidentally changed, they should

be restored to default factory settings shown in Table 25

“Parameter Descriptions”.

Parameters permitted to be ﬁeld adjusted are non-

shaded ones in Table 25. In order to change these

parameters, three subsequent tasks must be performed:

Also, Parameters 2 and 3 (see Table 25) should

be left at factory settings they could be changed

inadvertently (for example, pushing and holding

“+” or “-” key while boiler is in Standby Mode

will change them). If the boiler does not respond

to a call from one or both thermostats, verify that

Parameters 2 and 3 are both “ON”.

1. Adjusting the target boiler supply temperature when

responding to call from an indirect water heater -

The default IWH target supply temperature is 180°F.

Since most indirect water heaters have ratings based

on 180°F boiler supply temperature, it should rarely

be necessary to adjust this parameter.

4. Communication, Fan Speed and Error Modes

In addition to providing access to all ﬁeld adjustable

parameters, entering the access code also provides

access to three additional mode menus using the

boiler keypad. These are shown in Figure 52:

2. Changing the boiler water reset curve - When an

outdoor temperature sensor is connected to a Alpine

boiler, the MCBA will adjust the target boiler supply

temperature based on outdoor temperature when

the boiler is responding to a call for central heat.

Figure 53 is a graph showing the target boiler supply

temperature as a function of outdoor temperature.

The curve shown in Figure 53 is that obtained with

the factory set parameters. The shape of this curve

may be changed by changing Parameters 4, 5, 6, and

7 as shown in Figure 53. Refer to Part I Section C

for the procedure to change parameters.

a. Communication Mode - This mode does not

currently have any function.

b. Fan Speed Mode - Allows the user to view the

blower fan speed (ﬁring rate is determined by fan

speed).

c. Error Mode - Pressing STEP while in Error mode

allows the user to see the six most recent error

codes.

If the outdoor sensor is not connected to the boiler,

ꢂ9

e. Open Gascom by selecting the “Gascom

1.0” icon on the desk top. Before using the

program for the ﬁrst time it must be conﬁgured

properly to work with the Alpine boiler and

your computer. Go to the menu bar and select

“Gascom” and then “Conﬁguration”. Refer to

the menu tree shown in Figure 55.

B. Adjusting Parameters via Personal Computer with

GCI Interface

1. Operating System Requirements

The GCI Interface requires a PC computer running a

Windows 98/NT/2000 or XP operating system. In

addition, the PC must have an open serial port.

2. Connecting Personal Computer to MCBA Control

a. Connect the serial cable from the GCI to the

computer.

i. From the drop down box labeled

“MCBA1400” select the “Standard

HR7A60Hz” option.

b. Plug in the GCI.

ii. From the drop down box labeled “Interface

c. Open the lower front jacket panel. Loosen the

screws holding the control cover and swing down

the control cover so that the control compartment

is open.

device” select the “CGI232” option.

iii. The “Communication port” setting is the

serial port on the PC to which the GCI

interface is connected. Most often this serial

port will be “COM1”.

d Connect the ribbon cable from the GCI into the

open receptacle on the MCBA next to the ribbon

cable from the boiler display/keypad (Figure 54).

iv. The “Gascom Directory” ﬁeld will contain

the correct ﬁeld and will not need to be

changed as long as you accepted all of the

default ﬁle locations during installation.

Otherwise, you will need to locate the

Gascom directory on your hard drive and

enter the correct path name in this ﬁeld.

3. Installing GCI Interface Gascom Software

a. Gascom is the name of the software, which

must be installed on personal computer in order

to communicate with MCBA control via GCI

Interface.

v. If you wish to access Parameters 5 to 42

enter “05” in the “Access Code” ﬁeld (the

access code will need to be entered every

time the Gascom program is reopened).

b. Insert the Gascom CD in your computer’s

CDROM drive and wait a few seconds for the

software to prompt you to continue setup. Select

“NEXT” to continue the installation. Follow

the prompts to install the software. U.S. Boiler

highly recommends accepting the default

directories recommended.

Changing Parameters

Open the Gascom Program

1. If not already done connect GCI PC Interface, and

install the Gascom software as described in Part II

of this manual and open the Gascom software.

c. The last screen allows the user to select whether

or not to restart the computer. The computer

must be restarted prior to using the Gascom

program.

2. Click on the “Parameters” menu on the top of the

screen.

d. U.S. Boiler recommends the user register the

software on the date of installation however

registration is not required. Registration gives

the user access to our technical support personnel

online as well as information about software

updates. To register the software click on the

“Gascom Online” icon on the desk top and

select “Registration”. You will be asked to ﬁll

out a short form including your e-mail address.

Once the form is submitted a return e-mail will

be sent to you conﬁrming the information you

entered along with your registration number.

3. Click on “Read from MCBA”. After a few seconds,

a list of parameters and their settings will appear

on the screen. Parameters which are not accessible

are grayed out. If the access code has not been

entered in the conﬁguration screen, this will include

Parameters 5-42. Parameters 43 and above are

always grayed out because they are inaccessible in

the ﬁeld.

Figure 5ꢁ: MCBa Control

Figure 55: gascom Menu Tree

4. Double-click on the desired parameter. A window

Using Gascom To Monitor The MCBA

will open with either a ﬁeld or a pull down list of

options will appear. Enter or select the desired

value for the parameter.

From the Monitor Menu select “Monitor MCBA”.

This will bring up a window which plots the following

information:

5. Click OK.

1. Temperatures:

6. Repeat Steps (3) - (5) to change any other desired

parameters.

Flow - Actual boiler supply temperature

Return - Actual Boiler return temperature

7. After all parameters have been changed, click on the

“Parameters” menu at the top of the screen and then

click on “Write to MCBA”. After a few seconds,

the display on the boiler will blink. This indicates

that the parameters are written to the control and are

in effect.

Outdoor - Temperature being read by outdoor sensor

if it is connected. If it is not, temperature reading is

“-22”.

Fluegas - Flue gas temperature

Set - Target boiler supply temperature

2. Status:

Field Adjustable Parameters

Refer to Field Adjustable Parameters under A.

Adjusting Parameters via Boiler Keypad on pages 76

and 79 of this manual.

Room - Room thermostat (“1” = Calling, “0” = Not

Calling)

Hotwater - Indirect water heater thermostat (“1” =

Calling, “0” = Not Calling)

2. If the signal is lower then 6 VDC, check the

continuity of the ground wire between the ignitor

and the junction box. If the ground wire is suspect

replace the ground wire.

Pump - Heating circulator (“1” = On, “0” = Off)

Air-switch - Status of air pressure switch (“1” =

Closed, “0” = Open)

3. If the ground wire is in good condition, remove

the ignitor and ﬂame sensor to inspect the ceramic

insulator for cracks. If none are found, sand off

any oxide deposits which formed on the electrodes.

If the insulator is cracked or the electrode cannot

be properly cleaned, replace the ignitor and ﬂame

sensor. When replacing the ignitor and ﬂame sensor,

be sure to replace the ignitor and ﬂame sensor

gasket as well.

Gaspressure - This is actually the status of the high

limit (“1” = Closed, “0” = Open)

GasValve - Status of gas valve (“1” = Open , “0” =

Closed)

Flame - Shows whether the MCBA detects the

presence of the burner ﬂame (“1” = Flame, “0” = No

Flame)

4. Other problems that can cause a low ﬂame signal

DHW Pump - Indirect water heater circulator (“1” =

On, “0” = Off)

include:

•

An improperly adjusted throttle (conﬁrm that the

CO₂is within the limits shown in the installation

manual).

3. RPM:

Fan - Actual speed of fan

Set - Target speed of fan.

•

Fouling of the burner (remove the burner and

clean with compressed air).

Reading the MCBA Error Log

Low inlet gas pressure (verify that gas pressure

is within the limits shown on the rating plate).

1. The MCBA keeps a log of the last six error codes.

To view these error codes select “Read from

MCBA” from the Error Menu.

Grounded 24 VAC or sensor wiring (this problem

will result in no ﬂame voltage reading, but will

normally not result in an E02 error because there

is still adequate ﬂame current).

2. This data can be saved as a ﬁle to disk by selecting

“Save to ﬁle” from the Error Menu or printed by

selecting “Print” from the same menu.

3. Error codes can also be removed from the memory

of the MCBA by selecting “Clear in MCBA” from

the Error Menu.

B. NTC Temperature Sensors

1. The supply, return, ﬂue, and outdoor reset sensors

used on the Alpine are of the resistance type.

III. Component Test Procedures

A. Flame Signal Check

2. The Table 27 shows the range of resistance values

for these sensors at various temperatures.

1. The ﬂame signal can be checked between terminal

number 7 on the low voltage terminal strip and

ground. A good signal reading should be 6 VDC or

greater.

Table 2ꢂ: nTC Sensor Resistance Values

8ꢀ

Xiii. Service and Maintenance

DangER

This boiler uses ﬂammable gas, high voltage electricity, moving parts, and very hot water under high

pressure. assure that all gas and electric power supplies are off and that the water temperature is cool

before attempting any disassembly or service.

Do not attempt any service work if gas is present in the air in the vicinity of the boiler. never modify,

remove or tamper with any control device.

WaRning

This boiler must only be serviced and repaired by skilled and experienced service technicians.

if any controls are replaced, they must be replaced with identical models.

Read, understand and follow all the instructions and warnings contained in all the sections of this

manual.

if any electrical wires are disconnected during service, clearly label the wires and assure that the wires

are reconnected properly.

never jump out or bypass any safety or operating control or component of this boiler.

Read, understand and follow all the instructions and warnings contained in aLL of the component

instruction manuals.

assure that all safety and operating controls and components are operating properly before placing

the boiler back in service.

3. Inspect the water and gas lines to verify they are

free from leaks. Call the service technician to make

repairs if required.

nOTiCE

Warranty does not cover boiler damage or

malfunction if the following steps are not

performed at the intervals speciﬁed.

CaUTiOn

Water leaks can cause severe corrosion damage

to the boiler or other system components.

A. Continuously:

1. Keep the area around the boiler free from

combustible materials, gasoline and other ﬂammable

vapors and liquids.

immediately repair any leaks found.

C. Annual Inspections and Service: In addition to

the inspections listed above the following should be

performed by a service technician once every year.

2. Keep the area around the combustion air inlet

terminal free from contaminates .

1. If equipped, test the low water cutoff by pressing

the “Test” button located at its end. The yellow

light should come on and “E12” should ﬂash on

the display. Push the reset button on the display to

restore normal operation. If the yellow light does

not come on, determine why the low water cutoff is

not working properly.

3. Keep the boiler room ventilation openings open and

unobstructed.

B. Monthly Inspections:

1. Inspect the vent piping and outside air intake piping

to verify they are open, unobstructed and free from

leakage or deterioration. Call the service technician

to make repairs if needed.

2. Follow the procedure for turning the boiler off

found in the Alpine™ Series Lighting and Operating

Instructions.

2. Inspect the condensate drain system to verify it is

leak tight, open and unobstructed. Call the service

technician if the condensate drain system requires

maintenance.

8ꢁ

10. Reinstall the burner, burner hood and fan/gas valve

assembly.

3. Inspect the wiring to verify the conductors are in

good condition and attached securely.

11. Reconnect any wiring which has been disconnected.

CaUTiOn

12. Inspect the heating system and correct any other

deﬁciencies prior to restarting the boiler.

Label all wires prior to disconnection when

servicing controls. Wiring errors can cause

improper and dangerous operation. Verify

proper operation after servicing.

13. Follow Section XI System Start-up before leaving

installation.

14. Perform the combustion test outlined in Section XI

System Start-up.

4. Remove the ignition electrode and inspect it for

oxides. Clean the oxides from the electrode with

steel wool. Do not use sandpaper for the cleaning.

Inspect the ceramic insulator for cracks and replace

the ignitor assembly if necessary. Check the ignitor

electrode spacing gap. Refer to Figure 56 “Ignitor

Electrode Gap” for details.

15. Verify that the system PH is between 8.2 and 9.5/.

16. Check for vent terminal obstructions and clean as

necessary.

D. Recommended Heating System Water Treatment

Products:

1. System Cleaning and Conditioning:

a. The following heating system water treatment

products are recommended for an initial existing

heating system sludge removal, initial boiler

cleaning from copper dust, ﬂux residue and any

boiler debris and for preventive treatment as

corrosion/scale inhibitors:

i. Fernox™ Restorer (universal cleaner, sludge

remover, scale remover, ﬂux residue/debris

remover, corrosion inhibitor)

Figure 56: ignitor Electrode gap

5. Remove the fan/gas valve assembly from the burner

hood. Inspect for lint and dust. If signiﬁcant lint

and dust are found, disassemble the fan/gas valve

assembly to expose the swirlplate and fan inlet (see

the exploded diagram in the parts list at the back of

this manual). Vacuum these parts as required, being

careful not to damage the vanes on the swirlplate.

ii. Fernox™ Protector (Alphi 11, CH#, Copal)

(sludge remover, corrosion inhibitor)

Follow manufacturer application procedure

for proper heating system/boiler cleaning

and preventive treatment.

Above referenced products are available

from Cookson Electronics Company, 4100

Sixth Avenue, Altoona, PA 16602, Tel:

(814) 946-1611 and/or selected HVAC

distributors. Contact US Boiler for speciﬁc

details.

6. Remove the burner hood to access the burner and

the combustion chamber.

7. Remove the burner and vacuum any dust or lint

from the burner. If the burner shows signs of

deterioration or corrosion, replace it immediately.

Inspect the burner gasket and replace, if necessary.

iii. Equivalent system water treatment products

may be used in lieu of products referenced

above.

8. Inspect the heat exchanger, clean and vacuum any

debris found on the surfaces. A soft nylon brush

must be used for cleaning. Remove insulation disc

and clean the surfaces by ﬂushing with clean water.

Drain and ﬂush the inside of the heat exchanger

and condensate collector. Do not use any cleaning

agents or solvents. Re-install insulation disc.

2. System Freeze Protection:

a. The following heating system freeze protection

products are recommended for Alpine boilers:

i. Fernox™ Protector Alphi 11 (combined

antifreeze and inhibitor).

Follow manufacturer application procedure

to insure proper antifreeze concentration and

inhibitor level.

Above referenced product is available from

Cookson Electronics Company, 4100 Sixth

Avenue, Altoona, PA 16602, Tel: (814) 946-

1611 and/or selected HVAC distributors.

9. Inspect the condensate trap to verify it is open and

free from debris. Inspect condensate line integrity

between boiler and condensate neutralizer (if used)

and condensate neutralizer and the drain. Clean/

repair if needed.

If the condensate neutralizer is used, check pH

before and after the neutralizer to determine

neutralizing effectiveness. Replace limestone chips

and clean out the neutralizer if needed.

f. Reconnect the switch wire pigtails to the boiler

wiring and secure with wire nuts.

b. Equivalent system freeze protection products

may be used in lieu of product referenced

above. In general, freeze protection for new or

existing systems must use specially formulated

glycol, which contains inhibitors, preventing

the glycol from attacking the metallic system

components. Insure that system ﬂuid contains

proper glycol concentration and inhibitor level.

The system should be tested at least once a year

and as recommended by the manufacturer of the

glycol solution. Allowance should be made for

expansion of the glycol solution.

g. Restore power supply to boiler. Fill up the trap

(see Section V “Condensate Disposal”) and

verify the switch operation.

2. Condensate Trap Removal and Reinstallation:

a. Disconnect power supply to boiler.

b. Remove two (2) wire nuts and disconnect

overﬂow switch wire pigtails from boiler wiring.

c. Disconnect pressure switch hose from

condensate trap.

d. Disconnect outside condensate compression

ﬁtting from condensate trap stab.

CaUTiOn

e. Using pliers, release spring clip securing the

overﬂow switch to condensate trap body and

remove the switch. Note that the switch has

factory applied silicon adhesive seal, which may

have to be carefully cut all around to facilitate

the switch removal.

Use only inhibited propylene glycol solutions

speciﬁcally formulated for hydronic systems.

Do not use ethylene glycol, which is toxic and

can attack gaskets and seals used in hydronic

systems.

f. Using pliers, release spring clip securing

condensate trap body to the heat exchanger

bottom drain stab.

E. Condensate Overﬂow Switch and Condensate Trap

Removal and Replacement:

For removal or replacement of the condensate overﬂow

switch and/or condensate trap follow the steps below.

For parts identiﬁcation, refer to Section XV “Repair

Parts”.

g. Firstly, pull the trap downwards to release from

the heat exchanger bottom drain stab; secondly,

pull the trap end from left side jacket panel

sealing grommet and remove the trap from

boiler.

1. Condensate Overﬂow Switch Removal and

Replacement:

h. To reinstall the trap, reverse above steps.

a. Disconnect power supply to boiler.

i. If the original condensate overﬂow switch is

to be re-used, follow the appropriate switch

removal steps from Condensate Overﬂow Switch

Removal and Replacement procedure above.

b. Remove two (2) wire nuts and disconnect

overﬂow switch wire pigtails from boiler wiring.

c. Using pliers, release spring clip securing the

overﬂow switch to condensate trap body and

remove the switch. Note that the switch has

factory applied silicon adhesive seal, which may

have to be carefully cut all around to facilitate

the switch removal.

j. Insure that fresh silicon sealant is applied to

the overﬂow switch threads, and the switch is

properly oriented relative to the trap body -

the arrow molded into the switch hex side end

must face down for proper switch operation.

See Figure 57 “Condensate Overﬂow Switch

Orientation” for details. Insure that pressure

switch hose is reconnected to the trap.

d. Insure the trap overﬂow switch port is not

obstructed with silicon seal debris, clean as

needed.

k. Restore power supply to boiler. Fill up the trap

(see Section V “Condensate Disposal”) and

verify the switch operation.

e. Apply silicon seal to the replacement switch

threads and install the switch into the trap

body making sure it is properly oriented - the

arrow molded into the switch hex end side

must face down for proper switch operation.

See Figure 57 “Condensate Overﬂow Switch

Orientation” for details.

8ꢂ

XiV: Troubleshooting

WaRning

Turn off power to boiler before replacing fuses or working on wiring.

A. Troubleshooting problems where no error code is displayed. Refer to Table 28 for problems and possible causes.

Table 28: no Error Code Displayed

CONDITION

POSSIBLE CAUSES

Display Blank, Fan off, LWCO lights off

• No 120VAC Power at boiler. Check breaker and wiring between breaker panel and boiler

• Loose 120VAC connection wiring between boiler J-Box and MCBA

• Blown “F1” fuse in MCBA (see Figure 58 for location). Replace with 5A fuse provided

Display Panel Blank, Fan running

• Defective AT250 transformer

Display reads “U.125” continuously, Fan running

• Blown “F3” fuse in MCBA (see Figure 58 for location). Replace with 4A slow-blow fuse

provided

Boiler not responding to call for heat,

Status code on display =”0” (see Figure 50)

• Boiler is not seeing call for heat. Check thermostat or zone wiring for loose connection,

miswiring, or defective thermostat/zone control.

• Loose ribbon cable

Boiler ﬁres, but display panel is blank

• Defective display

Figure 58: MBCa Fuse Location

B. Trouble shooting problems where a soft lockout code is displayed. When a soft lockout occurs, the boiler will shut down

and the display will alternate between the number “9” and the letter “b” followed by a two digit service code. The boiler will

automatically restart once the condition that caused the lockout is corrected.

Table 29: Soft Lockout Codes Displayed

CODE CONDITION

POSSIBLE CAUSES

• Blockage in intake or vent system.

• Vent and/or intake system not constructed in accordance with Part VI.

• Blocked or leaking pressure switch tubing

• Heat exchanger or burner blockage

b 08

Pressure switch circuit open

• Terminals exposed to high winds

• Blockage in condensate trap above vent.

• Heating load at time of error was far below the minimum ﬁring rate of the

boiler

MCBA supply sensor detected temperatures in excess

of 200°F

b 18

b 19

• Defective primary pump or no ﬂow in primary loop (Piping Method 1)

• Control system miswired so that boiler operation is permitted when no zones

are calling

• See possible causes for “b18”

• Flow through boiler reversed

• Sensor wiring reversed

MCBA return sensor detected temperatures in excess

of 200°F

• Flow through boiler reversed. Verify correct piping and pump orientation.

• No boiler water ﬂow. Verify that system is purged of air and that appropriate

valves are open.

MCBA is reading a return sensor temperature higher

than the supply sensor temperature. Condition must be

present for at least 75s for this error code to appear.

b 24

b 25

• Sensor wiring reversed.

• Supply or return sensor defective.

• See possible causes for “b18”

Supply water temperature has risen too quickly

• Inadequate boiler water ﬂow. Verify that pump is operating and that pump

and piping are sized per Part VIII of this manual

• See possible causes for “b18”

Boiler safety limit, or external limit wired across

terminals 3&4, is open.

b 26

b 30

• Defective supply sensor.

Temperature rise between supply and return is too

high.

• Inadequate boiler water ﬂow. Verify that pump is operating and that pump

and piping are sized per Part VIII of this manual

• Blockage in pressure switch hose

• Pressure switch wires shorted together

• Defective pressure switch

b 61

b 65

Pressure switch circuit closed with fan off

Fan is not achieving set point speed

• Loose or miswired fan speed harness (if “b61” error code is observed while

fan is running)

• Loose or incorrect fan speed control connection

• Defective fan

the condition that caused the lockout is corrected, the

boiler will need to be manually reset using the RESET

button on the display.

C. Trouble shooting problems where a hard lockout

code is displayed. When a hard lockout occurs, the

boiler will shut down and the display will ﬂash the

letter “E” followed by a two digit service code. Once

Table ꢀ0: Hard Lockout Codes Displayed

CODE

CONDITION

POSSIBLE CAUSES

A ﬂame signal was present when there should

be no ﬂame.

• Defective gas valve - make sure inlet pressure is below maximum on rating plate

before replacing valve.

E 00

• No gas pressure

• Gas pressure under minimum value shown on rating plate

• Gas line not completely purged of air

• Defective Electrode

E 02

Flame failure after 5 tries to restart

• Loose burner ground connection

• Defective Ignition Cable

• Defective gas valve (check for 24 VDC at harness during trial for ignition before

replacing valve)

• Air-fuel mixture out of adjustment - consult factory

• Loose or defective gas valve harness. Check electrical connections.

• Defective gas valve (check for 24 VDC at harness during trial for ignition before

replacing valve)

E 03

E 04

Gas valve error

• Some other error on this list occurred and power to the boiler was then

interrupted. Reset control and see if hard lockout reoccurs.

Power failure occurred after lockout

E 05

E 06

E 07

E 11

Internal control failure

• Reset the control. If problem reoccurs, replace the MCBA.

• If yellow light on LWCO is on, system is low on water

• If neither yellow nor green light is on, check LWCO harness and check for

24VAC across AT140 transformer

E 12

Low water cut-off circuit open

E 13

E 14

E 15

E 16

E 17

Internal control failure

• Reset the control. If problem reoccurs, replace the MCBA.

MCBA supply sensor detected temperatures in

excess of 200°F for an extended period of time

E 18

E 19

• See possible causes for “b18” error. Also, check safety limit for proper operation.

• See possible causes for “b19” error.

MCBA return sensor detected temperatures in

excess of 200°F for an extended period of time

• Loose connection in 120 VAC fan wiring

• Loose or miswired fan speed harness

• Defective fan

Blower is not running when it should or fan speed

signal not being detected by MCBA

E 28

• Miswired fan speed harness

• Defective fan

E 29

E 31

E 32

E 35

E 36

E 37

Blower fan speed has not returned to zero rpm

Shorted supply temperature sensor

• Shorted or miswired supply sensor wiring

• Defective supply sensor

• Shorted or miswired return sensor wiring

• Defective return sensor

Shorted return temperature sensor

• Shorted or miswired ﬂue temp sensor wiring

• Defective ﬂue temp sensor

Flue gas temperature sensor short circuit

Supply water temperature sensor circuit open

Return water temperature sensor circuit open

• Loose or miswired supply sensor wiring

• Defective supply sensor

• Loose or miswired return sensor wiring

• Defective return sensor

• Loose or miswired ﬂue temp sensor wiring

• Defective ﬂue temp sensor

E 40

E 44

Flue gas temperature sensor circuit open

Internal control failure

• Reset the control. If problem reoccurs, replace the MCBA.

• Heat exchanger needs to be cleaned

• Boiler over-ﬁred

E 52

Flue gas temperature over 230°F

• Air-fuel mixture out of adjustment - consult factory

E 60

Internal control failure

• Reset the control. If problem reoccurs, replace the MCBA.

XV. Repair Parts

All Alpine™ Series Repair Parts may be obtained through your local Burnham Wholesale distributor.

Should you require assistance in locating a Burnham distributor in your area, or have questions regarding

the availability of Burnham products or repair parts, please contact Burnham Customer Service at

(717) 481-8400 or Fax (717) 481-8408.

(Quantity) Part Number

ALP150 ALP210

Key

No.

Description

ALP080

ALP105

ALP285

ALP399

Heat Exchanger, Burner, Etc. (Key No’s 2 thru 23)

Heat Exchanger Assembly

101520-01 101521-01 101522-01 101523-01 101524-01 101525-01

101710-01 101711-01 101712-01 101713-01 101714-01 101715-01

101717-01 101718-01 101719-01 101720-01 101721-01 101722-01

(6) 101724-01

Burner Assembly

M6x1 Hex Flange Nut (Not Shown)

Gas/Air Intake Duct Assembly (Not Shown)

Gas/Air Intake Duct Weldment (Not Shown)

Burner Plate (Not Shown)

101725-01

101725-02

N/A

101727-01

Burner Plate Insulation

(Warning: Contains RCF, Not Shown)

101728-01

Burner Plate Inner Seal (Not Shown)

Burner Plate Outer Seal (Not Shown)

Burner Head (Not Shown)

Burner Head Seal (Not Shown)

Ignitor

101729-01

101730-01

101731-01 101731-02 101731-03 101731-04 101731-05 101731-06

101732-01

101733-01

101734-01

101735-01

101736-01

101737-01

Flame Sensor

Observation Glass Retaining Plate

Observation Glass

Observation Glass Gasket

M3x6 mm Socket Hd Thread Forming Screw,

T10 Drive (Not Shown)

(2) 101738-01

Ignitor Gasket (Not Shown)

101740-01

101741-01

Flame Sensor Gasket (Not Shown)

M4x8 mm Socket Hd Cap Thread Forming Screw,

X20 Drive (Not Shown)

(4) 101739-01

M5x14 mm Pan Hd Thread Forming Screw, T25 Drive

(Not Shown)

101742-01

Insulation Disc (Warning: Contains RCF, Not Shown)

Air Vent Valve

101996-01

101586-01

(2) 101685-01

101653-01

101454-01

Water Temp Sensor

High Limit

Wire Harness (Not Shown)

(Quantity) Part Number

ALP150 ALP210

Key

No.

Description

ALP080

ALP105

ALP285

ALP399

Gas Train Assembly

(Key No’s 24 thru 29)

101585-01 101585-02 101585-03 101585-04 101585-05 101585-06

Blower

101527-01

101704-01

101528-01 101529-01

101704-02 101704-03

101345-01

N/A

101703-04 101703-05 101703-06

Included with Gas Valve (Key 28)

101530-01

Blower Inlet Shroud Assembly

Blower Outlet Gasket

Blower Mounting Plate

Gas Valve

101704-04

101703-01

101703-03

Gas Valve Harness with Plug

9ꢀ

(Quantity) Part Number

ALP150 ALP210

Key

No.

Description

ALP080

ALP105

ALP285

ALP399

Air Pressure Switch

80160762

7016039

101862-01

7016046

Air Pressure Switch Hose

Rubber Grommet, Condensate Trap

Condensate Trap, Blow Molded

Spring Clip, Condensate Trap

Blocked Condensate Drain Switch

Condensate Comp. Fitting

101595-01

101239-01

(2) 101632-01

101587-01

101546-01

9ꢁ

(Quantity) Part Number

ALP150 ALP210

Key

No.

Description

ALP080

ALP105

ALP285

ALP399

Wiring Harness (Not Shown)

101454-01

MCBA Slide Out Assembly

(Includes all parts shown)

101230-01

101219-01

Control Panel, MCBA

10186

6-05

45A MCBA (programmed - 0-2000’ or 0-7000’) 101866-01 101866-02 101866-03 101866-04

101866-06

45B MCBA (programmed - 2001 - 7000’)

101866-08 101866-09 101866-10 101866-11

N/A

MCBA Transformer

100474-01

100450-01

101331-01

101609-01

(4) 101636-01

MCBA Display Board

MCBA Display Board Cable

Label, MCBA Display

MCBA Display Spacer

(Quantity) Part Number

ALP150 ALP210

Key

No.

Description

ALP080

ALP105

ALP285

ALP399

Rubber Grommet, Gas Line

Jacket, Rear/Bottom Panel

Lower Front Door Assembly

Draw Latch

820SOL0001

101217-02 101217-03 101217-04 101764-01 101764-02

101227-01 101227-02

101638-01

101217-01

101037-01

Jacket, Left Side Panel

Jacket, Right Side Panel

Partition Shelf Assembly

Jacket Support Bracket

Jacket, Top Panel

101215-01

101216-01

101536-01

101215-02 101215-03 101215-04 101765-01 101765-02

101216-02 101216-03 101216-04 101766-01 101766-02

101536-02 101536-03 101536-04 101536-05 101536-06

101593-01

101218-01

101232-01

101224-01

101218-02 101218-03 101218-04 101218-05 101218-06

101232-02 101232-03 101232-04 101232-05 101232-06

101224-02 101224-03 101224-04 101224-05 101224-06

101326-01

Bracket Assembly, Right Side

Side Bracket

Junction Box Cover

Bracket, Rear HX Support

Bracket, Left Clip

101381-01

101507-01

101507-02

Bracket, Right Clip

101508-01

101245-01

101509-01

Rubber Pad, Right Clip

Jacket, Upper Front Panel

Gasket, Header (All Three)

Gasket, Header, 1” NPT

Gasket, Header, 1” & 3/4” NPT

Gasket, Header, Duo Size

101240-01

N/A

101243-01

101252-01

N/A

101372-02 101372-03

101372-01

(Quantity) Part Number

ALP150 ALP210

Key

No.

Description

ALP080

ALP105

ALP285

ALP399

Flue Temp Sensor

101687-01

101454-01

Wire Harness (Not Shown)

Concentric Vent Collar with Viton Cap

Vent Terminal Kit

101598-01

101808-01

101599-01

101809-01

9ꢂ

(Quantity) Part Number

ALP150 ALP210

Key No. Description

ALP080

ALP105

ALP285

ALP399

101777-01

101777-02

101777-03

MiSCELLanEOUS PaRTS CaRTOn

Temperature/Pressure Gauge

External Gas Shut Off Valve

Relief Valve

8056169

806SOL0005

81660363

101615-01

81660302

Boiler Drain Valve

806603061

(4) 101679-01

(12) 80860743

(1) 101639-01

Boiler Stacking Brackets

Boiler Stacking Bracket Screws

Outdoor Temperature Sensor

important Product Safety information

Refractory Ceramic Fiber Product

Warning:

The Repair Parts list designates parts that contain refractory ceramic fibers

(RCF). RCF has been classified as a possible human carcinogen. When

exposed to temperatures about 1805°F, such as during direct flame contact,

RCF changes into crystalline silica, a known carcinogen. When disturbed as a

result of servicing or repair, these substances become airborne and, if inhaled,

may be hazardous to your health.

AVOID Breathing Fiber Particulates and Dust

Precautionary Measures:

Do not remove or replace RCF parts or attempt any service or repair work

involving RCF without wearing the following protective gear:

1. A National Institute for Occupational Safety and Health (NIOSH)

approved respirator

2. Long sleeved, loose fitting clothing

3. Gloves

4. Eye Protection

• Take steps to assure adequate ventilation.

• Wash all exposed body areas gently with soap and water after contact.

• Wash work clothes separately from other laundry and rinse washing

machine after use to avoid contaminating other clothes.

• Discard used RCF components by sealing in an airtight plastic bag. RCF

and crystalline silica are not classified as hazardous wastes in the United

States and Canada.

First aid Procedures:

• If contact with eyes: Flush with water for at least 15 minutes. Seek

immediate medical attention if irritation persists.

• If contact with skin: Wash affected area gently with soap and water.

Seek immediate medical attention if irritation persists.

• If breathing difficulty develops: Leave the area and move to a location

with clean fresh air. Seek immediate medical attention if breathing

difficulties persist.

• Ingestion: Do not induce vomiting. Drink plenty of water. Seek

immediate medical attention.

Limited Warranty

FOR RESIDENTIAL GRADE STAINLESS STEEL WATER BOILERS

Subject to the terms and conditions set forth below, U.S. Boiler Company, Inc.

e. Boilers installed outside the 48 contiguous United States, the State of Alaska,

and Canada.

Lancaster, Pennsylvania hereby extends the following limited warranties to the

original owner of a residential grade stainless steel water boiler manufactured and

shipped on or after november 1, 2007:

f. Damage to the boiler and /or property due to installation or operation of the

boiler that is not in accordance with the boiler installation and operating instruction

manual.

ONEYEAR LIMITED WARRANTY ON RESIDENTIAL

STAINLESS STEEL GRADE WATER BOILERS

g. Any damage of failure of the boiler resulting from hard water or scale buildup in the

heat exchanger.

U.S. Boiler Company, Inc. warrants to the original owner that its residential grade

stainless steel water boilers comply at the time of manufacture with recognized

hydronic industry standards and requirements then in effect and will be free of

defects in material and workmanship under normal usage for a period of one year

from the date of original installation. If any part of a stainless steel water boiler is

found to be defective in material or workmanship during this one year period, U.S.

Boiler Company, Inc. will, at its option, repair or replace the defective part.

h. Any damage caused by improper fuels, fuel additives or contaminated combustion

air that may cause ﬁreside corrosion and/or clogging of the burner or heat

exchanger.

i. Any damage resulting from combustion air contaminated with particulate which

cause clogging of the burner or combustion chamber including but not limited to

sheetrock or plasterboard particles, dirt, and dust particulate. (See Air Ventilation

section of the Installation and Operating Manual furnished with the unit)

TWELVEYEAR LIMITED WARRANTY ON HEAT EXCHANGER

The second through 7th year warranty covers only the heat exchanger. All other

component parts furnished by U.S. Boiler Company, Inc., but purchased from other

manufacturers, shall be limited to their warranties, if any.

j. Any damage, defects or malfunctions resulting from improper operation,

maintenance, misuse, abuse, accident, negligence including but not limited to

operation with insufﬁcient water ﬂow, improper water level, improper water

chemistry, or damage from freezing. (See System Piping, Start up and Checkout,

Operation and Service and Maintenance sections of the Installation and

Operating Manual furnished with the unit)

U.S. Boiler Company, Inc. warrants to the original owner and at its original place

of installation that the heat exchanger of its residential grade stainless steel water

boilers will remain free from defects in material and workmanship under normal

usage for seven years. If a claim is made under this warranty during the ﬁrst seven

years from the date of original installation, U.S. Boiler Company, Inc. will, at its

option, repair or replace the heat exchanger. If a claim is made under this warranty

after the expiration of seven years and up to twelve years from the date of original

installation, U.S. Boiler Company, Inc. will, at its option and upon payment of the

pro-rated service charge set forth below, repair or replace the stainless steel heat

exchanger. The service charge applicable to a stainless steel heat exchanger

warranty claim is based upon the number of years the heat exchanger has been

in service and will be determined as a percentage of the retail price of the heat

exchanger model involved at the time the warranty claim is made as follows:

k. Any damage caused by water side clogging due to dirty systems or corrosion

products from the system. (See System Piping section of the Installation and

Operating Manual furnished with the unit)

l. Any damage resulting from natural disaster.

m. Damage or malfunction due to the lack of required maintenance outlined in the

Service and Maintenance section of the Installation and Operating Manual

furnished with the unit.

6. Exclusive Remedy: U.S. Boiler Company, Inc. obligation for any breach of these

warranties is limited to the repair or replacement of its parts in accordance with the

terms and conditions of these warranties.

years in Service

1-7

13 +

100

7. Limitation of Damages: Under no circumstances shall U.S. Boiler Company,

Inc. be liable for incidental, indirect, special or consequential damages of any kind

whatsoever under these warranties, including, but not limited to, injury or damage to

persons or property and damages for loss of use, inconvenience or loss of time. U.S.

Boiler Company, Inc. liability under these warranties shall under no circumstances

exceed the purchase price paid by the owner for the residential grade water boiler

involved. Some states do not allow the exclusion or limitation of incidental or

consequential damages, so the above limitation or exclusion may not apply to you.

Service Charge

as % of

Retail Price

Charge

nOTE: If the heat exchanger model involved is no longer available due to product

obsolescence or redesign, the value used to establish the retail price will be the

published price as shown in the Burnham hydronics Repair Parts Price Sheet

where the heat exchanger last appeared or the current retail price of the then

nearest equivalent heat exchanger.

8. Limitation of Warranties: These warranties set forth the entire obligation of U.S.

Boiler Company, Inc. with respect to any defect in a residential grade stainless

steel water boiler and U.S. Boiler Company, Inc. shall have no express obligations,

responsibilities or liabilities of any kind whatsoever other than those set forth herein.

These warranties are given in lieu of all other express warranties.

ADDITIONAL TERMS AND CONDITIONS

1. Applicability: The limited warranties set forth above are extended only to the

original owner at the original place of installation within the United States and

Canada. These warranties are applicable only to stainless steel water boilers

designated as residential grade by U.S. Boiler Company, Inc. and installed in a

single or two-family residence and do not apply to steam boilers of any kind, any

application other than for space heating or to commercial grade boilers.

ALL APPLICABLE IMPLIED WARRAnTIES, If Any, InCLUDIng Any WARRAnTy

Of MERChAnTABILITy OR fITnESS fOR A PARTICULAR PURPOSE ARE

ExPRESSLy LIMITED In DURATIOn TO A PERIOD Of OnE yEAR ExCEPT ThAT

IMPLIED WARRAnTIES, If Any, APPLICABLE TO ThE hEAT ExChAngER In A

RESIDEnTIAL STAInLESS STEEL gRADE WATER BOILER ShALL ExTEnD TO

ThE ORIgInAL OWnER fOR A MAxIMUM Of TWELVE yEARS AT ThE ORIgInAL

PLACE Of InSTALLATIOn. SOME STATES DO nO ALLOW LIMITATIOn On hOW

LOng An IMPLIED WARRAnTy LASTS, SO ThE ABOVE LIMITATIOn MAy nOT

APPLy TO yOU.

2. Components Manufactured by Others: Upon expiration of the one year limited

warranty on residential grade stainless steel water boilers, all boiler components

manufactured by others but furnished by U.S. Boiler Company, Inc. (such as

burners, gas valves and controls) will be subject only to the manufacturer’s

warranty, if any.

PROCEDURE FOR OBTAINING WARRANTY SERVICE

3. Proper Installation: The warranties extended by U.S. Boiler Company, Inc. are

conditioned upon the installation of the residential grade stainless steel water boiler

in strict compliance with U.S. Boiler Company, Inc. installation instructions. U. S.

Boiler Company, Inc. speciﬁcally disclaims liability of any kind caused by or relating

to improper installation.

In order to assure prompt warranty service, the owner is requested to complete and

mail the attached Warranty Card within ten days after the installation of the boiler,

although failure to comply with this request will not void the owner’s rights under these

warranties.

Upon discovery of a condition believed to be related to a defect in material or

workmanship covered by these warranties, the owner should notify the installer, who

will in turn notify the distributor. If this action is not possible or does not produce a

prompt response, the owner should write to U.S. Boiler Company, Inc., Burnham

hydronics, at P.O. Box 3079, Lancaster, PA 17604, giving full particulars in support

of the claim.

4. Proper Use and Maintenance: The warranties extended by U.S. Boiler Company,

Inc. conditioned upon the use of the residential grade stainless steel water boiler for

its intended purposes and its maintenance in accordance with U.S. Boiler Company,

Inc. requirements and hydronics industry standards.

5. This warranty does not cover the following:

a. Expenses for removal or re-installation. The homeowner will be responsible for

the cost of removing and reinstalling the alleged defective part or its replacement

and all labor and material connected therewith, and transportation to and from

U.S. Boiler Company, Inc.

The owner is required to make available for inspection by U.S. Boiler Company, Inc.

or its representative the parts claimed to be defective and, if requested by U.S. Boiler

Company, Inc. to ship these parts prepaid to U.S. Boiler Company, Inc. at the above

address for inspection or repair. In addition, the owner agrees to make all reasonable

efforts to settle any disagreement arising in connection with a claim before resorting

to legal remedies in the courts.

b. Components that are part of the heating system but were not furnished by

U.S. Boiler Company, Inc., as part of the residential boiler.

c. Improper burner adjustment, control settings, care or maintenance.

ThIS WARRAnTy gIVES yOU SPECIfIC LEgAL RIghTS AnD yOU MAy ALSO

hAVE OThER RIghTS WhICh VARy fROM STATE TO STATE.

d. This warranty cannot be considered as a guarantee of workmanship of an

installer connected with the installation of the U.S. Boiler Company, Inc. boiler,

or as imposing on U.S. Boiler Company, Inc. liability of any nature for

unsatisfactory performance as a result of faulty workmanship in the installation,

which liability is expressly disclaimed.

10/07

100

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