Alpine ALP080B Service manual

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

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IMPORTANT INFORMATION - READ CAREFULLY
NOTE: The equipment shall be installed in accordance with those installation regulations enforced in the area where the
installation is to be made. These regulations shall be carefully followed in all cases. Authorities having jurisdiction
shall be consulted before installations are made.
All wiring on boilers installed in the USA shall be made in accordance with the National Electrical Code and/or local regulations.
All wiring on boilers installed in Canada shall be made in accordance with the Canadian Electrical Code and/or local regulations.
The 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.

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Special Installation Requirements for Massachusetts
A. For all sidewall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or
in part for residential purposes and where the sidewall exhaust vent termination is less than seven (7) feet above grade, the
following requirements shall be satised:
1. If there is no carbon monoxide detector with an alarm already installed in compliance with the most current edition of
NFPA 720, NFPA 70 and the Massachusetts State Building Code in the residential unit served by the sidewall horizontally
vented gas fueled equipment, a battery operated carbon monoxide detector with an alarm shall be installed in compliance
with the most current edition of NFPA 720, NFPA 70 and the Massachusetts State Building Code.
2. In addition to the above requirements, if there is not one already present, a carbon monoxide detector with an alarm
and a battery back-up shall be installed and located in accordance with the installation requirements supplied with the
detector on the oor level where the gas equipment is installed. The carbon monoxide detector with an alarm shall
comply with 527 CMR, ANSI/UL 2034 Standards or CSA 6.19 and the most current edition of NFPA 720. In the event
that the requirements of this subdivision can not be met at the time of the completion of the installation of the equipment,
the installer shall have a period of thirty (30) days to comply with this requirement; provided, however, that during
said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed in compliance
with the most current edition of NFPA 720, NFPA 70 and the Massachusetts State Building Code. In the event that the
sidewall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the carbon monoxide detector
may be installed on the next adjacent habitable oor level. Such detector may be a battery operated carbon monoxide
detector with an alarm and shall be installed in compliance with the most current edition of NFPA 720, NFPA 70 and the
Massachusetts State Building Code.
3. A metal or plastic identication plate shall be permanently mounted to the exterior of the building at a minimum height
of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled
heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, “GAS VENT
DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.
4. A nal inspection by the state or local gas inspector of the sidewall horizontally vented equipment shall not be performed
until proof is provided that the state or local electrical inspector having jurisdiction has granted a permit for installation of
carbon monoxide detectors and alarms as required above.
B. EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a) 1 through 4:
1. The equipment listed in Chapter 10 entitled “Equipment Not Required To Be Vented” in the most current edition of NFPA
54 as adopted by the Board; and
2. Product Approved sidewall horizontally vented gas fueled equipment installed in a room or structure separate from the
dwelling, building or structure used in whole or in part for residential purposes.
C. When the manufacturer of Product Approved sidewall horizontally vented gas equipment provides a venting system design
or venting system components with the equipment, the instructions for installation of the equipment and the venting system
shall include:
1. A complete parts list for the venting system design or venting system; and
2. Detailed instructions for the installation of the venting system design or the venting system components.
D. When the manufacturer of a Product Approved sidewall horizontally vented gas fueled equipment does not provide the parts
for venting ue gases, but identies “special venting systems”, the following shall be satised:
1. The referenced “special venting system” instructions shall be included with the appliance or equipment installation
instructions; and
2. The “special venting systems” shall be Product Approved by the Board, and the instructions for that system shall include a
parts list and detailed installation instructions.
E. A copy of all installation instructions for all Product Approved sidewall horizontally vented gas fueled equipment, all venting
instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or
equipment at the completion of the installation.

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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

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I. Product Description, Specications and Dimensional Data
Alpine™ Series boilers are condensing high efciency
gas-red direct vent hot water heating boilers designed
for use in forced hot water space or space heating with
indirect domestic hot water heating systems, where supply
water temperature does not exceed 210°F. These boilers
have special coil type stainless steel heat exchangers,
constructed, tested and stamped per Section IV ‘Rules
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)
14
(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)
18
(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.

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Figure 1A: Models ALP080B through ALP210B (Floor Mounted)
I. Product Description, Specications and Dimensional Data (continued)

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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.