Alpine ALP080B Service-Handbuch

103448-06 - 4/15 Price - $5.00

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

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

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

injury, or loss of life. For assistance or additional information, consult a qualied installer, service agency or the

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

9700609

INSTALLATION, OPERATING AND

SERVICE INSTRUCTIONS FOR

ALPINE™

CONDENSING HIGH EFFICIENCY

DIRECT VENT

GAS - FIRED HOT WATER BOILER

Size Range - 80 MBH through 285 MBH

2 103448-06 - 4/15

IMPORTANT INFORMATION - READ CAREFULLY

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

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

shall be consulted before installations are made.

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

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

The following terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to

important information concerning product life.

The City of New York requires a Licensed Master Plumber supervise the installation of this product.

The Massachusetts Board of Plumbers and Gas Fitters has approved the Alpine™ Series boiler. See the Massachusetts Board of

Plumbers and Gas Fitters website, http://license.reg.state.ma.us/pubLic/pl_products/pb_pre_form.asp for the latest Approval

Code or ask your local Sales Representative.

The Commonwealth of Massachusetts requires this product to be installed by a Licensed Plumber or Gas Fitter.

DANGER

Indicates an imminently hazardous situation

which, if not avoided, will result in death, serious

injury or substantial property damage.

CAUTION

Indicates a potentially hazardous situation which,

if not avoided, may result in moderate or minor

injury or property damage.

WARNING

Indicates a potentially hazardous situation which,

if not avoided, could result in death, serious injury

or substantial property damage.

NOTICE

Indicates special instructions on installation,

operation, or maintenance which are important

but not related to personal injury hazards.

DANGER

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

appliance.

If you smell gas vapors, NO NOT try to operate any appliance - DO NOT touch any electrical switch or use

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

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

103448-06 - 4/15 3

Special Installation Requirements for Massachusetts

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

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

following requirements shall be satised:

1. If there is no carbon monoxide detector with an alarm already installed in compliance with the most current edition of

NFPA 720, NFPA 70 and the Massachusetts State Building Code in the residential unit served by the sidewall horizontally

vented gas fueled equipment, a battery operated carbon monoxide detector with an alarm shall be installed in compliance

with the most current edition of NFPA 720, NFPA 70 and the Massachusetts State Building Code.

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

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

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

comply with 527 CMR, ANSI/UL 2034 Standards or CSA 6.19 and the most current edition of NFPA 720. In the event

that the requirements of this subdivision can not be met at the time of the completion of the installation of the equipment,

the installer shall have a period of thirty (30) days to comply with this requirement; provided, however, that during

said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed in compliance

with the most current edition of NFPA 720, NFPA 70 and the Massachusetts State Building Code. In the event that the

sidewall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the carbon monoxide detector

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

detector with an alarm and shall be installed in compliance with the most current edition of NFPA 720, NFPA 70 and the

Massachusetts State Building Code.

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

of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled

heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, “GAS VENT

DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.

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

until proof is provided that the state or local electrical inspector having jurisdiction has granted a permit for installation of

carbon monoxide detectors and alarms as required above.

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

1. The equipment listed in Chapter 10 entitled “Equipment Not Required To Be Vented” in the most current edition of NFPA

54 as adopted by the Board; and

2. Product Approved sidewall horizontally vented gas fueled equipment installed in a room or structure separate from the

dwelling, building or structure used in whole or in part for residential purposes.

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

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

shall include:

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

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

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

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

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

instructions; and

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

parts list and detailed installation instructions.

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

instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or

equipment at the completion of the installation.

4 103448-06 - 4/15

TABLE OF CONTENTS

I. Product Description, Specications and Dimensional Data...................... 5

II. Unpacking Boiler........................................................................................ 9

III. Pre-Installation and Boiler Mounting ........................................................ 10

IV. Venting...................................................................................................... 17

A. General Guidelines............................................................................... 17

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

C. Polypropylene Venting......................................................................... 29

D. Stainless Steel Venting........................................................................ 33

E. Removing the Existing Boiler............................................................... 37

F. Multiple Boiler Installation Venting....................................................... 38

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

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

VII. Gas Piping ............................................................................................... 57

VIII. Electrical ................................................................................................... 61

IX. System Start-up ....................................................................................... 75

1. Operation...................................................................................................... 83

A. Overview............................................................................................... 83

B. Supply Water Temperature Regulation................................................ 84

C. Boiler Protection Features.................................................................... 85

D. Multiple Boiler Control Sequencer........................................................ 86

E. Boiler Sequence of Operation.............................................................. 87

1. Normal Operation........................................................................... 87

2. Using The Display.......................................................................... 88

3. Status Screens.............................................................................. 89

4. Detail Screens............................................................................... 91

5. Multiple Boiler Sequencer Screens................................................ 92

F. Changing Adjustable Parameters........................................................ 93

1. Entering Adjust Mode.................................................................... 93

2. Adjusting Parameters..................................................................... 93

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

XII. Troubleshooting........................................................................................ 117

XIII. Repair Parts ............................................................................................. 122

Appendix A - Figures................................................................................ 132

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

103448-06 - 4/15 5

I. Product Description, Specications and Dimensional Data

Alpine™ Series boilers are condensing high efciency

gas-red direct vent hot water heating boilers designed

for use in forced hot water space or space heating with

indirect domestic hot water heating systems, where supply

water temperature does not exceed 210°F. These boilers

have special coil type stainless steel heat exchangers,

constructed, tested and stamped per Section IV ‘Rules

for Construction of Heating Boilers’ of ASME Boiler and

Pressure Vessel Code, which provide a maximum heat

transfer and simultaneous protection against ue gas product

corrosion. These boilers are not designed for use in gravity

hot water space heating systems or systems containing

signicant amount of dissolved oxygen (swimming pool

water heating, direct domestic hot water heating, etc.).

Dimension Boiler Model

ALP080B (1) ALP105B (1) ALP150B (1) ALP210B (1) ALP285B (2)

A - Inch

(mm)

12-9/16

(320)

(356)

19-11/16

(500)

23-15/16

(608)

21-13/16

(554)

B - Inch

(mm)

5-5/8

(142)

5-13/16

(147)

7-5/16

(185)

C - Inch

(mm)

7-5/16

(186)

14-1/8

(358)

D - Inch

(mm)

9-5/16

(237)

10-3/4

(273)

16-7/16

(417)

17-1/8

(435)

(456)

E - Inch

(mm)

5-15/16

(151)

12-1/4

(312)

Gas Inlet F

(FPT) 1/2” 3/4”

Return G

(FPT) 1” 1-1/4”

Supply H

(FPT) 1” 1-1/4”

Condensate Drain J * * Factory Provided Socket End Compression Pipe Joining Clamp

for 3/4” Schedule 40 PVC Pipe

Boiler Two-Pipe

CPVC/PVC Vent Connector

(Figs. 1A, 1C) - Inch

3 x 3 3 x 4 4 x 4

Boiler

CPVC Vent Connector/Pipe

(Fig. 1B) - Inch

3” N/A

Boiler Inlet Air Connector

(Fig. 1B) - Inch 3” 3” 4” 4” N/A

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

NOTES:

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

(2) - This boiler model available as Floor mounted (sufx F) only.

Specication Boiler Model

ALP080B ALP105B ALP150B ALP210B ALP285B

Altitude (ft. above sea level) 0-4500 0-4500 0-4500 0-4500 0-4500

Fuel Shipped for Natural Gas, Field Converted for LP Gas

Max. Allowable Water Temperature (°F) 210

Max. Allowable Working Pressure (psi) 160

Factory supplied Safety Relief Valve (psi) * 30

Boiler Water Volume (gal.) 0.6 0.7 1.3 1.7 2.4

Heat Transfer area (sq. ft.) 7.3 9.1 16.4 21.8 29.1

Approx. Shipping weight (lb.) 137 155 182 206 256

Table 1A: Specications

* Optional 50 psi, 80 psi and 100 psi safety relief valves are available for all models.

6 103448-06 - 4/15

Figure 1A: Models ALP080B through ALP210B (Floor Mounted)

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

103448-06 - 4/15 7

Figure 1B: Models ALP080B through ALP210B (Wall or Floor Mounted)

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

8 103448-06 - 4/15

Figure 1C: Model ALP285B (Floor Mounted)

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

103448-06 - 4/15 9

Table 2: Ratings

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

Alpine Series Gas-Fired Boilers

* Model Number Input (MBH) ** Output

(MBH)

Net AHRI Ratings Water 1

(MBH)

AFUE

(%)

Min. Max.

ALP080B 16 80 72 63 95

ALP105B 21 105 96 83 95

ALP150B 30 150 136 118 95

ALP210B 42 210 194 169 95

ALP285B 57 285 262 228 95

Ratings shown are for installations at sea level and elevations up to 2000 ft. For elevations above 2000 ft., the boiler will

naturally derate by 2.5% for each 1000 ft. above sea level.

1 Net AHRI Water Ratings based on allowance of 1.15. Consult manufacturer before selecting boiler for installations

having unusual piping and pickup requirements, such as intermittent system operation, extensive piping systems, etc.

II. Unpacking Boiler

CAUTION

Do not drop boiler.

A. Move boiler to approximate installed position.

B. Remove all crate fasteners.

C. Lift and remove outside container.

D. Remove boiler from cardboard positioning sleeve on

shipping skid.

WARNING

Installation of this boiler should be undertaken

only by trained and skilled personnel from a

qualied service agency.

E. Move boiler to its permanent location.

10 103448-06 - 4/15

WARNING

Explosion Hazard. Asphyxiation Hazard.

Electrical Shock Hazard. Installation of this

boiler should be undertaken only by trained

and skilled personnel from a qualied service

agency. Follow these instructions exactly.

Improper installation, adjustment, service,

or maintenance can cause property damage,

personal injury or loss of life.

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. U.S.

Boiler Company DOES NOT warrant failures

caused by mis-sized boiler applications. DO

NOT oversize the boiler to the system. Multiple

boiler installations greatly reduce the likelihood

of boiler oversizing.

WARNING

Asphyxiation Hazard.

Models with Two-Pipe Vent Connector:

Apply supplied dielectric grease to gasket inside

vent section of two-pipe vent connector. Failure

to apply the grease could result in ue gas leaks

from gasket rupture during vent pipe installation

or gasket deterioration due to condensate

exposure.

A. Installation must conform to the requirements

of the authority having jurisdiction in or, in the absence

of such requirements, to the National Fuel Gas Code,

ANSI Z223.1/NFPA 54, and/or Natural Gas and

Propane Installation Code, CAN/CSA B149.1.

Where required by the authority having jurisdiction, the

installation must conform to the Standard for Controls

and Safety Devices for Automatically Fired Boilers,

ANSI/ASME CSD1.

B. Boiler is certied for installation on

combustible ooring. Do not install boiler on

carpeting.

C. Provide clearance between boiler jacket and

combustible material in accordance with local re

ordinance. Refer to Figure 2A or 2B for minimum listed

clearances from combustible material. Recommended

service clearance is 24 in. (610 mm) from left side,

III. Pre-Installation and Boiler Mounting

front, top and rear of the boiler. Recommended front

clearance may be reduced to the combustible material

clearance providing:

1. Access to boiler front is provided through a door

or removable front access panel.

2. Access is provided to the condensate trap

located underneath the heat exchanger.

3. Access is provided to thermal link located at

boiler rear.

D. Protect gas ignition system components

from water (dripping, spraying, rain, etc.) during

boiler operation and service (circulator replacement,

condensate trap, control replacement, etc.).

E. Provide combustion and ventilation air in

accordance with applicable provisions of local building

codes, or: USA - National Fuel Gas Code, ANSI

Z223.1/NFPA 54, Air for Combustion and Ventilation;

Canada - Natural Gas and Propane Installation Code,

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

Appliances.

WARNING

Asphyxiation Hazard. Adequate combustion and

ventilation air must be provided to assure proper

combustion. Install combustion air intake per

Section IV “Venting”.

F. The boiler should be located so as to minimize

the length of the vent system. The combustion air

piping must terminate where outdoor air is available for

combustion and away from areas that may contaminate

combustion air. In particular, avoid areas near chemical

products containing chlorines, chlorouorocarbons,

paint removers, cleaning solvents and detergents.

Avoid areas containing saw dust, loose insulation bers,

dry wall dust etc.

NOTICE

Avoid operating this boiler in an environment

where sawdust, loose insulation bers, dry wall

dust, etc. are present. If boiler is operated under

these conditions, the burner interior and ports

must be cleaned and inspected daily to insure

proper operation.

G. General

1. Alpine boilers are intended for installations

in an area with a oor drain or in a suitable drain

pan to prevent any leaks or relief valve discharge to

cause property damage.

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