U.S. Boiler Company Alpine ALP080B, Installation, Operating And Service Instructions

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52 103448-10- 6/18
V. Condensate Disposal
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
XI “Service and Maintenance” for condensate
trap and condensate overflow switch removal
and replacement procedure, if required.
3. Note the following when disposing of the
condensate:
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.
b. Do not route or terminate the condensate
drain line in areas 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.
d. Do not attempt to substitute another trap for
one provided with the boiler.
e. In order for boiler to work properly, the
boiler must be leveled during installation.
4. The condensate trap connection is located
at boiler left side, below inlet and outlet water
pipe connections. Refer to Figures 1A, 1B, 1C
and 19.
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 (240ml) through
condensate trap connection. Do not overfill the
trap.
6. Install tee for condensate overflow and vent as
shown in Figure 19.
7. If any additional condensate drain line is
needed, construct the extension from PVC or
CPVC Schedule 40 pipe. The factory supplied
¾ in. x 5-5/8 in. long PVC coupling, located in
the miscellaneous parts carton, must be used
to connect drain line to the condensate trap.
Do not over tighten coupling compression nuts
when connecting drain line and condensate
trap.
8. Size condensate drain line, pump and
neutralizer (if using other than manufacturer
neutralizer kit) to accommodate maximum
condensate flow shown in Table 11 “Maximum
Condensate Flow”.
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.
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.
WARNING Asphyxiation Hazard. Failure
to fill the condensate trap with water prior to
boiler start-up could cause flue gas to enter
the building, resulting in personal injury or
death.
WARNING Asphyxiation Hazard. Failure
to install the condensate drain in accordance
with the above instructions could cause flue
gas to enter the building, resulting in personal
injury or death.
NOTICE Boiler condensate is corrosive. Route
condensate drain line in a manner such
that any condensate leakage will not cause
property damage.
• Some jurisdictions may require that
condensate be neutralized prior to disposal.
• Use materials approved by the authority
having jurisdiction.