Burnham Water boiler Service manual

101602-01R9-9/10 Price - $5.00
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As an ENERGY STAR®Partner, Burnham by 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

2
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.

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 OFALL 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
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 efciency.
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 ttings nor attempt
to disconnect any components of this boiler without positively assuring the water is cool and has no
pressure. Always wear protective clothing and equipment when installing, starting up or servicing this
boiler to prevent scald injuries. Do not rely on the pressure and temperature gauges to determine the
temperature and pressure of the boiler. This boiler contains components which become very hot when
the boiler is operating. Do not touch any components unless they are cool.
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.
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.

5
TABLE OF CONTENTS
I. Product Description, Specications and Dimensional Data...................... 6
II. Pre-Installation & Boiler Mounting ............................................................ 13
III. Unpacking Boiler........................................................................................ 17
IV. Venting...................................................................................................... 18
A. GeneralGuidelines............................................................................... 18
B. CPVC/PVCVenting.............................................................................. 21
C. Stainless Steel Venting........................................................................ 29
D. Concentric Polypropylene.................................................................... 31
E. Removing the Existing Boiler............................................................... 38
V. Condensate Disposal................................................................................. 39
VI. Water Piping and Trim............................................................................... 41
VII. Gas Piping ................................................................................................ 50
VIII. Electrical ................................................................................................... 54
IX. Boiler Stacking ......................................................................................... 61
X. Modular Installation................................................................................... 63
A. General Guidelines.............................................................................. 63
B. Venting................................................................................................ 63
C. Water Piping and Trim......................................................................... 66
D. Gas Piping........................................................................................... 66
E. Electrical.............................................................................................. 76
F. External Modular Boiler Controls......................................................... 76
G. Modular Boiler Operating Information.................................................. 77
1. MajorFeatures............................................................................... 77
2. Operating Modes........................................................................... 79
3. Required Equipment and Setup..................................................... 81
4. Adjusting Parameters.................................................................... 83
XI. System Start-up ...................................................................................... 86
XII. Operation ................................................................................................. 92
A. MajorFeatures..................................................................................... 92
B. Operating Mode................................................................................... 96
1. Home Screen................................................................................ 96
2. Boiler Status Screen...................................................................... 97
C. Controls Start-up Checklist.................................................................. 98
D. User Interface...................................................................................... 99
1. Using The Display.......................................................................... 99
2. Selecting View Mode Options........................................................ 99
3. Help Screens................................................................................. 100
4. Entering Adjust Mode.................................................................... 101
E. AdjustingParameters........................................................................... 102
XIII. Service and Maintenance ......................................................................... 110
XIV. Troubleshooting........................................................................................ 114
XV. Repair Parts ............................................................................................. 117
Appendix B - Figures................................................................................ 126
Appendix C - Tables.................................................................................. 129
Warranty...........................................................................................Back Page

6
I. Product Description, Specications and Dimensional Data
Alpine™ Series boilers are condensing high efciency
gas-red 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
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
ALP080 (1) ALP105 (1) ALP150 (1) ALP210 (1) ALP285 (2) ALP399 (2) ALP500 (2)
A - Inch
(mm)
12-9/16
(320)
14
(356)
19-11/16
(500)
23-15/16
(608)
21-13/16
(554)
28-7/8
(734)
44-7/8
(1140)
B - Inch
(mm)
5-5/8
(142)
5-13/16
(147)
7-5/16
(185)
6-3/16
(157)
22-1/8
(562)
C - Inch
(mm)
7-5/16
(186)
14-1/8
(358)
13-1/16
(332)
29
(737)
D - Inch
(mm)
9-5/16
(237)
10-3/4
(273)
16-7/16
(417)
17-1/8
(435)
18
(456)
23-3/4
(602)
39-11/16
(1008)
E - Inch
(mm)
5-15/16
(151)
12-1/4
(312)
15-13/16
(402)
29-3/8
(752)
Gas Inlet F
(FPT) 1/2” 3/4” 3/4” 3/4”
Return G
(FPT) 1” 1-1/4” 1-1/2”
Supply H
(FPT) 1” 1-1/4” 1-1/2”
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, 1D) - Inch
3 x 3 3 x 4 4 x 4
Boiler
CPVC Vent Connector/Pipe
(Fig. 1B) - Inch
3” N/A N/A N/A
Boiler Inlet Air Connector
(Fig. 1B) - Inch 3” 3” 4” 4” N/A N/A N/A
Approx. Shipping Weight
(LBS) 137 155 182 206 256 304 350
Table 1: Dimensional Data (See Figures 1A, 1B, 1C & 1D)
NOTES:
(1) - These boiler models available as either Floor mounted (sufx F) or, Wall mounted (sufx W).
(2) - These boiler models available as Floor mounted (sufx F) only.

7
Figure 1A: Alpine™ - Models ALP080 thru ALP210 (Floor Mounted)
I. Product Description, Specications and Dimensional Data (continued)

8
Figure 1B: Alpine™ - Models ALP080 thru ALP210 (Wall Mounted)
I. Product Description, Specications and Dimensional Data (continued)

9
Figure 1C: Alpine™ - Models ALP285 thru ALP399 (Floor Mounted Only)
I. Product Description, Specications and Dimensional Data (continued)

10
Figure 1D: Alpine™ - Model ALP500 (Floor Mounted Only)
I. Product Description, Specications and Dimensional Data (continued)

11
Table 2A: Rating Data - Models ALP080 thru ALP500 (0 to 2000 Feet Elevation Above Sea Level)
Table 2B: Rating Data - Models ALP080 thru ALP500 (2001 to 7000 Feet Elevation Above Sea Level)
I. Product Description, Specications and Dimensional Data (continued)
Alpine Series Gas-Fired Boilers
* Model
Number
Input
(MBH) ** Output
(MBH)
Net I=B=R
Ratings
Water (MBH)
AFUE
%
Thermal
Efciency
(%)
Combustion
Efciency (%)
Boiler Water
Volume
(Gal.)
Heat Transfer
Area
(Sq. Ft.)
Min. Max.
ALP080 16 80 73 63 95 0.6 7.3
ALP105 21 105 96 83 95 0.7 9.1
ALP150 30 150 138 120 95 1.3 16.4
ALP210 42 210 194 169 95 1.7 21.8
ALP285 57 285 265 230 95 2.4 29.1
ALP399 80 399 377 328 94 95 3.4 41.8
ALP500 100 500 475 413 95 95 4.2 50.8
* Add Sufx “F” for Floor mounted Models or Sufx “W” for Wall mounted Models.
Notes: ** DOE Heating Capacity (ALP080 thru ALP285); Gross Output (ALP399 thru ALP500)
Maximum Working Pressure, Water - 30 PSI Shipped from Factory (std.); 50 PSI, 80 PSI and 100 PSI - Optional (ALP080 thru ALP285)
Maximum Working Pressure, Water - 50 PSI Shipped from Factory (std.); 80 PSI and 100 PSI - Optional (ALP399 thru ALP500)
Maximum Allowable Temperature, Water - 210°F, Maximum Firing Rate Target Setpoint is 190°F, Automatic Reset High Limit Setpoint
is 200°F and Manual Reset High Limit Setpoint is 210°F.
Boilers are factory shipped as Natural Gas builds and have to be eld adjusted for LP gas application. Refer to ‘System Start-
Up Section of 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.
Alpine Series Gas-Fired Boilers
Model
Number *
Input
(MBH) ** Output
(MBH)
Net I=B=R
Ratings
Water (MBH)
AFUE
%
Thermal
Efciency
(%)
Combustion
Efciency (%)
Boiler Water
Volume
(Gal.)
Heat Transfer
Area (Sq. Ft.)
Min. Max.
ALP080 27 80 73 63 95 0.6 7.3
ALP105 35 105 96 83 95 0.7 9.1
ALP150 50 150 138 120 95 1.3 16.4
ALP210 70 210 194 169 95 1.7 21.8
ALP285 57 285 265 230 95 2.4 29.1
ALP399 80 399 377 328 94 95 3.4 41.8
ALP500 100 500 475 413 95 95 4.2 50.8
* Add Sufx “F” for Floor mounted Models or Sufx “W” for Wall mounted Models.
Notes: ** DOE Heating Capacity (ALP080 thru ALP285); Gross Output (ALP399 thru ALP500)
Maximum Working Pressure, Water - 30 PSI Shipped from Factory (std.); 50 PSI, 80 PSI and 100 PSI - Optional
Maximum Working Pressure, Water - 50 PSI Shipped from Factory (std.); 80 PSI and 100 PSI - Optional (ALP399 thru ALP500)
Maximum Allowable Temperature, Water - 210°F, Maximum Firing Rate Target Setpoint is 190°F, Automatic Reset High Limit Setpoint
is 200°F and Manual Reset High Limit Setpoint is 210°F.
Boilers are factory shipped as Natural Gas builds and have to be eld adjusted for LP gas application. Refer to ‘System Start-
Up” Section of 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.

12
I. Product Description, Specications and Dimensional Data (continued)
Table 2C: Rating Data - Models ALP150 thru ALP285 (7001 to 10,000 Feet Elevation Above Sea Level)
Alpine Series Gas-Fired Boilers
Model
Number *
Input
(MBH) ** Output
(MBH)
Net I=B=R
Ratings
Water (MBH)
AFUE
%
Thermal
Efciency
(%)
Combustion
Efciency (%)
Boiler Water
Volume
(Gal.)
Heat Transfer
Area (Sq. Ft.)
Min. Max.
ALP150 38 113 104 90 95 1.3 16.4
ALP210 53 158 145 126 95 1.7 21.8
ALP285 68 204 188 163 95 2.4 29.1
* Add Sufx “F” for Floor mounted Models or Sufx “W” for Wall mounted Models.
Notes: ** DOE Heating Capacity (ALP150 thru ALP285)
Maximum Working Pressure, Water - 30 PSI Shipped from Factory (std.); 50 PSI - Optional
Maximum Allowable Temperature, Water - 210°F
Boilers are factory shipped as Natural Gas builds only.
Input has been de rated for noted elevation above sea level.

13
WARNING
If you do not follow these instructions exactly,
a re or explosion may result causing property
damage or personal injury.
NOTICE
Due to the low water content of the boiler, 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
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.
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 certied for installation on
combustible ooring. Do not install boiler on
carpeting.
C. Provide clearance between boiler jacket and
combustible material in accordance with local re
ordinance. Refer to Figures 2A and 2B for minimum
listed clearances from combustible material.
Recommended service clearance is 24 inches from left
side, front, top and rear of the boiler. Recommended
front clearance may be reduced to the combustible
material clearance providing:
1. Access to boiler front is provided through a door or
removable front access panel.
2. Access is provided to the condensate trap located
underneath the heat exchanger.
D. Protect gas ignition system components from water
(dripping, spraying, rain, etc.) during boiler operation
and service (circulator replacement, condensate trap,
control replacement, etc.).
E. Provide combustion and ventilation air in accordance
with applicable provisions of local building codes,
or: USA - National Fuel Gas Code, NFPA 54/ANSI
Z223.1, Air for Combustion and Ventilation;
Canada - Natural Gas and Propane Installation Code,
CAN/CSA-B149.1, Venting Systems and Air Supply for
Appliances.
WARNING
Adequate combustion and ventilation air must
be provided to assure proper combustion.
II. Pre-Installation & Boiler Mounting
F. 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uorocarbons , paint
removers, cleaning solvents and detergents. Avoid
areas containing saw dust, loose insulation bers, dry
wall dust etc.
CAUTION
Avoid operating this boiler in an environment
where saw dust, loose insulation bers, dry wall
dust, etc. are present. If boiler is operated under
these conditions, the burner interior and ports
must be cleaned and inspected daily to insure
proper operation.
G. General.
1. Alpine boilers are intended for installations in an
area with a oor drain, or, in a suitable drain pan to
prevent any leaks or relief valve discharge to cause
property damage
2. Alpine boilers are not intended to support external
piping and venting. All external piping and venting
must be supported independently of the boiler.
3. Alpine boilers must be installed level to prevent
condensate from backing up inside the boiler.
4. Alpine boilers can be installed either as oor
standing (ALP080 thru ALP500), or, as wall hung
(ALP080 thru ALP210). Factory assembled oor
standing models are identied with sufx F in a
boiler model code (example – ALP210F-1L02).
Factory assembled wall hung models are identied
with sufx W in a boiler model code (example
– ALP210W-1L02).
5. Boiler Floor Standing Installation:
a. For basement installation provide a solid base
such as concrete, where oor is not level, or,
water may be encountered on the oor around
boiler. Floor must be able to support weight
of boiler, water and all additional system
components.
b. Boiler must be level to prevent condensate from
backing up inside the boiler.
c. Insure there is adequate space for condensate
piping or a condensate pump if required.

14
6. Boiler Wall Hung Installation:
a. If the boiler is installed on a framed wall,
minimum acceptable framing is 2 x 4 studs on
16” centers. The boiler mounting holes are on
16” centers for installation between two studs
at the standard spacing. In cases where the
boiler cannot be centered between the studs, or
where the studs are spaced closer than 16” apart,
the boiler may be anchored to ¾” plywood or
horizontal 2 x 4’s anchored to the studs.
CAUTION
Alpine boiler approximate dry weights:
ALP080W – 98 lbs; ALP105W – 112 lbs;
ALP150W – 136 lbs: ALP210W – 150 lbs
Two people are required to safely lift these
boilers onto the installed wall mounting
bracket.
Make sure that wall mounting bracket is an-
chored to a structure capable of supporting
the weight of the boiler and attached piping
when lled with water. Jurisdictions in areas
subject to earthquakes may have special re-
quirements for supporting these boilers. Such
local requirements take precedence over the
requirements shown below.
b. Locate Wall Mounting Bracket Kit carton (p/n
102988-01) enclosed inside boiler carton. The
kit contains Wall Mounting Bracket, Bottom
Securing Bracket, (4) 5/16” x 2” long hex head
lag screws, (4) 5/16” at plated washers and (2)
#8 x ½” Phillips round head sheet metal screws.
c. 5/16” x 2” lag screws and 5/16” plated washers
are intended for mounting the boiler directly
onto studs covered with ½” sheet rock. When the
boiler is attached to other types of construction,
such as masonry, use fasteners capable of
supporting the weight of the boiler and attached
piping in accordance with good construction
practice and applicable local codes.
d. Make sure that the surface to which the boiler is
mounted is plumb.
e. Before mounting the boiler, make sure that wall
selected does not have any framing or other
construction that will interfere with the vent pipe
penetration.
f. Once a suitable location has been selected for the
boiler, and any needed modications have been
made to the wall, use Figure 2C to locate and
layout holes “A” and “B”. These holes must be
positioned on mounting stud centers, if the boiler
is installed on a framed wall. Make sure that
the horizontal centerline of these holes is level.
Holes “C” and “D” may also be drilled at this
time, or after the boiler is hung on the wall. If the
5/16 x 2” lag screws are used, drill 3/16” pilot
holes.
g. An alternate way to locate/mark holes “A”
and “B” is to use template P/N 102986-01
enclosed into Vent Part Carton [P/N 102981-
01 (ALP080W/105W) or, P/N 102981-02
(ALP150W/210W)], which can be found inside
boiler carton.
CAUTION
The outer edges of the template represent
minimum side, top and bottom clearances to
combustible material. If the template needs to be
cut to t into a selected location, it would indicate
the minimum clearances to combustible material
are not met.
h. Attach the wall hanging bracket using the 5/16”
x 2” lag screws and 5/16” plated washers, or
other suitable anchors as appropriate (Figure
2D). Make sure the bracket is level.
i. Attach Bottom Securing Bracket to boiler air box
with two #8 x ½” Phillips round head sheet metal
screws. Refer to Figure 2D for details.
j. Hang the boiler on the installed wall bracket as
shown in Figure 2D.
k. If not already done in Step (4) locate and drill
holes “C” and “D” using the ob-round slots in
the Bottom Securing Bracket. Secure the Bracket
to the wall using the 5/16” x 2” lag screws
and 5/16” plated washers, or other fasteners as
appropriate (Figure 2D).
l. Verify that the front of the boiler is plumb. If it
is not, install shims (installer provided) at holes
“C” and “D” between the Bottom Securing
Bracket and the wall to adjust.
CAUTION
When positioning the template in the desired
location on the wall insure that the minimum
clearances to combustible material at
adjacentwallsandceilingaremaintained. Consult
Figures 2A thru 2C in this manual. Be sure to
allow space at the boiler left side for gas and
water connections, as well as for access to the
condensate trap and boiler controls for servicing.
m. Remove Access Panel and Access Panel Gasket
from zip lock plastic bag (placed inside 102981-
01 or 102981-02 Vent Kit carton).
II. Pre-Installation & Boiler Mounting (continued)

15
Figure 2A: Clearances To Combustible and Non-combustible Material, Floor Standing
Figure 2B: Clearances To Combustible and Non-combustible Material, Wall Mounted
II. Pre-Installation & Boiler Mounting (continued)

16 Figure 2C: Wall Mounting Hole Location / Layout
TOP EDGE OF BOILER
'HOLE C'
'HOLE A'
'HOLE D'
LEFT SIDE OF BOILER
1.0" MIN. CLEARANCE TO COMBUSTIBLE
10.0" MIN. CLEARANCE TO COMBUSTIBLES
16
253
4
WALL MOUNTING BRACKET
CENTER LINE
BOTTOM SECURING
BRACKET CENTER LINE
2.0" MIN. CLEARANCE TO COMBUSTIBLE
'HOLE B'
3
16" DIA. PILOT HOLES
FOR 5
16" LAG SCREWS
(4 PLACES)
n. Place Access Panel Gasket adhesive side
(protective paper) down onto Access Panel
underside and align gasket edges ush with panel
edges. Peel off protective paper from one end
of the gasket to expose adhesive, then place the
gasket onto the panel aligning gasket and panel
side, top and bottom edges, and press the gasket
lightly down. Continue peeling of protective
paper and positioning the gasket in place while
insuring edge alignment. Once the gasket is
fully in place and edges are aligned, press the
gasket rmly in position.
o. Set the panel with gasket aside.
p. See Section IV Venting; paragraph “Field
Installation of CPVC Vent Pipe - Wall Mounted
Boiler Builds” for instructions on attaching the
vent system to the boiler.
q. After the boiler has been piped, wired, connected
to vent and combustion air system piping and
combustion performance testing completed per
Section XI “System Start-up”, install Access
Panel/Gasket assembly and secure with provided
four #8 x ½” black oxide Phillips head sheet
metal screws (located in coin envelope inside zip
lock plastic bag). See Figure 2E “access Panel
and Gasket Installation”.
II. Pre-Installation & Boiler Mounting (continued)

17
III. 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.
Figure 2D: Bottom Mounting Bracket Installation / Boiler Wall Mounting
Figure 2E: Access Panel and Gasket Installation
II. Pre-Installation & Boiler Mounting (continued)

18
IV. Venting
A. General Guidelines
1. Vent system installation must be in accordance
with National Fuel Gas Code, NFPA 54/ANSI
Z221.3 or applicable provisions of local building
codes. Contact local building or re ofcials about
restrictions and installation inspection in your area.
2. The Alpine™ is designed to be installed as a
Direct Vent (sealed combustion) boiler. The air
for combustion is supplied directly to the burner
enclosure from outdoors and ue gases are vented
directly outdoors (through wall or roof).
3. The following combustion air/vent system options
are approved for use with the Alpine™ boilers (refer
to Table 3):
• Two-Pipe CPVC/PVC Vent/Combustion Air
System - separate CPVC/PVC pipe serves to
expel products of combustion and separate PVC
pipe delivers fresh outdoor combustion air.
Refer to Part B for specic details.
• Two-Pipe Stainless Steel Vent/CombustionAir
System - separate stainless steel pipe serves to
expel products of combustion. Separate PVC or
galvanized pipe delivers fresh outdoor air. Refer
to Part C for specic details.
• Concentric Inner Polypropylene Vent
and Outer Steel Combustion Air System
- the assembly consists of inner re resistant
polypropylene vent pipe and outer steel pipe
casing. The inner pipe serves as conduit to
expel products of combustion, while outdoor
fresh combustion air is drawn through the space
between the inner and outer pipes. Refer to Part
D for specic details.
4. Horizontal vent pipe must maintain a 1/4" per foot
slope down towards the boiler.
5. Horizontal combustion air pipe must maintain a
minimum ¼" per foot slope down towards terminal,
when possible. If not, slope toward boiler.
6. Do not install venting system components on
the exterior of the building except as specically
required by these instructions (refer to Figure 3):
• Vent terminals must be at least 1 foot from any
door, window, or gravity inlet into the building.
• Maintain the correct clearance and orientation
between the vent and air intake terminals. The
vent and air intake terminals must be at the same
height and their center lines must be spaced apart
12” minimum. Locate air intake termination on
the same wall as the vent termination if possible,
WARNING
Failure to vent this boiler in accordance with these instructions could cause products of combustion to
enter the building resulting in severe property damage, personal injury or death.
Do not interchange vent systems or materials unless otherwise specied.
The use of thermal insulation covering pipe and ttings is prohibited.
Do not use a barometric damper, draft hood or vent damper with this boiler.
When using the CPVC/PVC vent option, the use of CPVC is required when venting in vertical or horizontal
chase ways.
The CPVC vent materials supplied with this boiler do not comply with B149.1.S1-07 and are not ap-
proved for use in Canadian jurisdictions that require vent systems be listed to ULC S636-2008. In
these jurisdictions, vent this boiler using either stainless steel Special Gas vent or a listed ULC S636
Class IIB venting system.
Do not locate vent termination where exposed to prevailing winds. Moisture and ice may form on
surface around vent termination. To prevent deterioration, surface must be in good repair (sealed,
painted, etc.).
Do not locate air intake vent termination where chlorines, chlorouorocarbons (CFC’s), petroleum
distillates, detergents, volatile vapors or other chemicals are present. Severe boiler corrosion and
failure will result.
The use of cellular core PVC (ASTM F891) is prohibited.
Do not locate vent termination under a deck.
Do not reduce specied diameters of vent and combustion air piping.
When installing vent pipe through chimney, as a chase, no other appliance can be vented into the
chimney.
Do not allow low spots in the vent where condensate may pool.

19
Boiler Build Approved Direct
Vent System Vent Material Orientation Termination Description Figures Component Table Part
Floor Standing
or Wall Hung
Two-Pipe,
CPVC/PVC
Vent and PVC
air intake
(Factory Standard)
CPVC/PVC
Horizontal
Standard
(thru sidewall)
The system includes separate
CPVC vent pipe and PVC air intake
pipe terminating thru sidewall with
individual penetrations for the vent
and air intake piping and separate
terminals (tees).
4 thru 9 4A
B.
Optional
Snorkel
(thru sidewall)
Same as above but separate snorkel
type terminals. 4, 5A, 5B, 6, 7, 9, 10 4B
Optional Vertical Vertical
(thru roof)
The system includes separate CPVC
vent pipe and PVC air intake pipe
terminating thru roof with individual
penetrations for the vent and air
intake piping and separate vertical
terminals.
4, 5A, 5B,
6, 9, 11 4C
Floor Standing
Only
Two-Pipe,
Stainless Steel Vent
and PVC/galvanized
steel air intake
(Available Optional)
Stainless Steel
Horizontal
Standard
(thru sidewall)
The system includes separate
stainless steel vent pipe and
PVC/galvanized steel air intake
pipe terminating thru sidewall with
individual penetrations for the vent
and air intake piping and separate
terminals
8, 13
8A & 8B C.
Optional
Snorkel
(thru sidewall)
Same as above but separate snorkel
type terminals. 10, 13
Vertical Vertical
(thru roof)
The system includes separate
stainless steel vent pipe and
PVC/galvanized steel air intake pipe
terminating thru roof with individual
penetrations for the vent and air
intake piping and separate terminals.
11, 12, 13
Floor Standing
Only
Concentric, Inner
Polypropylene Vent
and Outer Steel Air
intake (Available
Optional)
Polypropylene
Horizontal Horizontal
(Wall) Terminal
Concentric vent/air pipe terminates
thru sidewall. 14 thru 21
10 D.
Vertical Vertical (Roof)
Terminal Concentric vent/air pipe terminates thru roof.
14, 15,
16, 17,
22 thru 26
Figure 3: Location of Vent Terminal Relative to Windows, Doors, Grades, Overhangs, Meters and Forced Air
Inlets (Concentric Terminal Shown - Two-Pipe System Vent Terminal to be installed in same location -
Two-Pipe System Air Intake Terminal Not Shown)
Table 3: Vent/Combustion Air System Options
IV. Venting (continued)

20
to prevent nuisance boiler shutdowns. However,
boiler may be installed with vertical venting
and sidewall combustion air inlet or visa versa,
if installation conditions do not allow alternate
arrangement.
• The bottom of the vent and air intake terminal
must be at least 12" (18" in Canada) above the
normal snow line. In no case should they be less
than 12" above grade level.
• The bottom of the vent terminal must be at least
7 feet above a public walkway.
• Do not install the vent terminal directly over
windows or doors.
• The bottom of the vent terminal must be at least
3 feet above any forced air inlet located within
10 feet.
• A clearance of at least 4 feet horizontally must
be maintained between the vent terminal and
gas meters, electric meters, regulators, and relief
equipment. Do not install vent terminal over this
equipment.
• Do not locate the vent terminal under decks or
similar structures.
• Minimum twelve (12) inches vertically from any
roof overhang twelve (12) inches or less wide.
If a roof overhang width exceeds twelve (12)
inches the terminal vertical clearance must be
increased to avoid ue vapor condensation.
• Top of vent terminal must be at least 5 feet below
eaves, softs, or overhangs. Maximum depth of
overhang is 3 ft.
• If window and/or air inlet is within four (4) feet
of an inside corner, then terminal must be at least
six (6) feet from adjoining wall of inside corner.
• Concentric - Minimum twelve (12) inches
horizontally from a building corner.
• Under certain conditions, water in the ue gas
may condense, and possibly freeze, on objects
around the terminal including on the structure
itself. If these objects are subject to damage by
ue gas condensate, they should be moved or
protected.
• If possible, install the vent and air intake
terminals on a wall away from the prevailing
wind. Reliable operation of this boiler cannot be
guaranteed if the terminal is subjected to winds
in excess of 40 mph.
• Air intake terminal must not terminate in areas
that might contain combustion air contaminates,
such as near swimming pools.
• For sidewall venting the minimum horizontal
distance between any adjacent individual module
(boiler) vent terminations is twelve (12) inches.
Increasing this distance is recommended to avoid
frost damage to building surfaces where vent
terminations are placed.
CAUTION
Installing multiple individual module (boiler) vent
terminationstooclosetogethermayresultincross
contamination and combustion product water
vapor condensation on building surfaces, where
vent termination are placed, and subsequent
frost damage. To avoid/minimize frost damage,
extend the distance from building surfaces to
vent termination end and increase the horizontal
distance between adjacent vent terminations.
• The minimum horizontal distance between any
adjacent individual module (boiler) roof vent
terminations is one (1) foot.
7. Use noncombustible ¾" pipe strap to support
horizontal runs and maintain vent location and
slope while preventing sags in pipe. Do not restrict
thermal expansion or movement of vent system.
Maximum support spacing four (4) feet. Avoid low
spots where condensate may pool. Do not penetrate
any part of the vent system with fasteners.
8. Maintain minimum clearance to combustible
materials. See Figures 2A and 2B for details.
9. Enclose vent passing through occupied or
unoccupied spaces above boiler with the material
having a re resistance rating of at least equal to the
rating of adjoining oor or ceiling.
Note: For one or two family dwellings, re
resistance rating requirement may not need to be
met, but is recommended.
10. Multiple individual module vertical vent pipes may
be piped through a common conduit or chase so that
one roof penetration may be made.
IV. Venting (continued)