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Burnham ALP105 Service Instructions Manual

Burnham corp. gas-fired hot water boiler installation, operating and service instructions.
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As an ENERGY STAR
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Partner, Burnham Hydronics has determined that the Alpine™ Series meets the ENERGY
guidelines for energy efficiency established by the United States Environmental Protection Agency (EPA).
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STAR
Improper installation, adjustment, alteration, service or maintenance can cause property damage,
WaRning:
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.
101602-01R2-9/08
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Price - $5.00

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   Summary of Contents for Burnham ALP105

  • Page 1

    As an ENERGY STAR ® Partner, Burnham Hydronics has determined that the Alpine™ Series meets the ENERGY guidelines for energy efficiency established by the United States Environmental Protection Agency (EPA). ® STAR Improper installation, adjustment, alteration, service or maintenance can cause property damage, WaRning: injury, or loss of life.

  • Page 2

    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/pb_pre_form.asp for the latest Approval Code or ask your local Sales Representative.

  • Page 3

    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.

  • Page 4: Table Of Contents

    XIII. Service and Maintenance ... 84 XIV. Troubleshooting ... 88 XV. Repair Parts ... 91 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...

  • Page 7

    (MBH) * Model ** Output Number (MBH) Min. Max. ALP080 ALP105 ALP150 ALP210 ALP285 ALP399 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.);...

  • Page 8: Ii. Pre-installation, Inch

    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.

  • Page 9: Iii. Unpacking Boiler

    Do not drop boiler. Move boiler to approximate installed position. Remove all crate fasteners. Lift and remove outside container. 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 qualified service agency.

  • Page 10: Iv. Venting

    Venting 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.

  • Page 11

    Direct Vent (sealed combustion) the concentric vent pipe VERTiCaL terminates vertically (through the 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.

  • Page 12

    Table 5: Clearances from Vent Piping to Combustible Material Vent Pipe CPVC/PVC Venting 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”...

  • Page 13

    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. 8. Design the Vent System to allow a 3/8” of thermal expansion per 10 feet of CPVC/PVC pipe. Runs of 20 ft.

  • Page 14

    7. Near-Boiler Vent Piping (see Figure 5): WaRning 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. a. All CPVC vent components (supplied with boiler), 30”...

  • Page 15

    Combustion air terminal can be installed closer to wall than vent. 5. Start at vent connector (rear boiler jacket) and work towards the combustion air terminal. 6. Size combustion air wall penetration to allow easy...

  • Page 16

    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.

  • Page 17

    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 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.

  • Page 18

    Combustion air terminal can be installed closer to roof than vent. 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...

  • Page 19

    Combination Concentric Gas Vent/Combustion air System (optional). 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.

  • Page 20

    Figure 12: Field installation of Boiler Concentric Vent Collar codes. Contact local building or fire officials about restrictions and installation inspection in your area. 2. Horizontal vent pipe must maintain a minimum ¼ inch per foot slope towards the boiler.

  • Page 21

    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. Concentric Venting - Horizontal Venting 1. Permitted terminals for horizontal venting:...

  • Page 22

    Figure 1: Horizontal (Wall) Terminal installation 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”’. Figure 1: Dimension “L” c. When factory supplied Horizontal (Wall) Terminal needs to be shortened, measure dimension “L”...

  • Page 23

    Continue installing additional concentric vent cuttable or non-cuttable piping as required. 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.

  • Page 24

    Reinstall the inner pipe. “Joining Cuttable Pipe” and Figure 24 “Joining Non-Cuttable Pipe” and follow the procedure below: 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.

  • Page 25

    Figure 2: Joining non-Cuttable 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.

  • Page 26

    CaUTiOn if the boiler is located directly under the hole, cover it while cutting the hole to prevent debris from falling onto boiler.

  • Page 27

    Table 10: Cut-To-Length Extensions (Cuttable) Part No. Component Description Cut-To-Length Extension, 101163-01 500 mm (19-1/2”) Cut-To-Length Extension, 101162-01 1000 mm (39”) Cut-To-Length Extension, 101550-01 500 mm (19-1/2”) Cut-To-Length Extension, 101551-01 1000 mm (39”) Chimney Chase Installation. A vertical concentric vent system, either 80/125 mm or 100/150 mm can be installed in an UNUSED masonry chimney.

  • Page 28

    Figure 28: Chimney Chase installation...

  • Page 29: V. Condensate Disposal

    V. Condensate Disposal 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.

  • Page 31: Vi. Water Piping And Trim

    Vi. Water Piping and Trim 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.).

  • Page 32

    1¼” x 1¼” x ¾” NPT black tee, ¾” x ¼” NPT black reducing bushing and Temperature & Pressure Gauge. 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.

  • Page 33

    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.

  • Page 34

    * 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. f. When Alliance SL™ model coil flow rate, g.

  • Page 37

    (red oxide sludge Fe 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.

  • Page 44

    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. 2. Direct connection of Alpine (ALP) boiler to...

  • Page 45

    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 the heat exchanger manufacturer for proper heat exchanger sizing as well as flow and temperature requirements.

  • Page 46: Vii. Gas Piping

    Minimum gas valve inlet pressure is stamped on the rating label located in the boiler’s vestibule compartment. 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).

  • Page 47

    Table 1B: 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 Size, In. Diameter, In. 0.622 ½ 0.824 ¾...

  • Page 48

    Correction Factor must be leak tested before placing boiler in operation. 0.82 1. Protect boiler gas control valve. For all testing over ½ psig, boiler and its individual shutoff valve must 0.78 be disconnected from gas supply piping. For testing 0.74...

  • Page 49: Viii. Electrical

    “Hot” leg of the power supply. Locate the 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.

  • Page 50

    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,...

  • Page 51

    Figure 5: Wiring Connections Diagram...

  • Page 52

    Figure 6: Ladder Diagram...

  • Page 53

    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...

  • Page 54

    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...

  • Page 55

    Figure 8: Wiring for MCBa Modulating Boiler Control Time Delay Relay Box 5. If the boiler installation site may be subject to low 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.

  • Page 56: Ix. Boiler Stacking, Inch

    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. • Place first Stacking Boiler Attachment Bracket...

  • Page 57

    (3) feet horizontally. 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.

  • Page 58: X. Modular Installation, Inch

    Modular Boiler Venting System Arrangements 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.

  • Page 61

    Modular Boiler Water Piping – (See Table 19 and Figure 42) Refer to Section VI “Water Piping and Trim” of these Instructions for: 1.

  • Page 66: Xi. System Start-up

    8. Purge gas line of air. Operating Instructions Start the boiler using the lighting instructions, see Figure 46. After the boiler is powered up, it should go through the following sequence. Display Sequence Meaning U.125...

  • Page 67

    Alpine™ Series Lighting and Operating Instructions Figure 6: Lighting instructions...

  • Page 68

    5 minutes before taking combustion readings. 3. Normal modulation of the boiler should return 15 minutes after the boiler is locked in high or low fire. Typical CO Each alpine Series boiler is tested at the factory and adjustments to the air fuel mixture are normally not necessary.

  • Page 69

    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.

  • Page 70

    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 range shown in this table.

  • Page 71

    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 2 could result in injury or death from carbon monoxide poisoning.

  • Page 72: Xii. Operation

    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.

  • Page 73

    Tfoot for 2nd CH circuit Thysteresis for 2nd CH circuit Pump settings for CH and DHW 42-1 Minimum Off Cycle (2nd digit) 42-2 * Circulator will start when boiler supply sensor will detect temperature 44.6° F or less Factory Setting ALP080 ALP105 ALP150 ALP210...

  • Page 75

    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.

  • Page 76

    • 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. Additionally, either the keypad or the personal computer can be used to obtain information about the boiler current status and operating history.

  • Page 77

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

  • Page 78

    Figure 52: Expanded Menu Tree (cont’d.) Figure 5: adjusting Boiler Water Reset Curve...

  • Page 79

    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”...

  • Page 80

    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. c. The last screen allows the user to select whether or not to restart the computer.

  • Page 81

    “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.

  • Page 82

    Hotwater - Indirect water heater thermostat (“1” = Calling, “0” = Not Calling) Pump - Heating circulator (“1” = On, “0” = Off) Air-switch - Status of air pressure switch (“1” = Closed, “0” = Open) Gaspressure - This is actually the status of the high limit (“1”...

  • Page 83

    Table 2: nTC Sensor Resistance Values...

  • Page 84: Xiii. Service And Maintenance

    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.

  • Page 85

    Re-install insulation disc. 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.

  • Page 86

    Orientation” for details. f. Reconnect the switch wire pigtails to the boiler wiring and secure with wire nuts. 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.

  • Page 88: Xiv. Troubleshooting

    • Blown “F3” fuse in MCBA (see Figure 58 for location). Replace with 4A slow-blow fuse provided • Boiler is not seeing call for heat. Check thermostat or zone wiring for loose connection, miswiring, or defective thermostat/zone control. • Loose ribbon cable •...

  • Page 89

    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.

  • Page 90

    • Defective gas valve (check for 24 VDC at harness during trial for ignition before replacing valve) • Some other error on this list occurred and power to the boiler was then interrupted. Reset control and see if hard lockout reoccurs.

  • Page 91: 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...

  • Page 92

    M5x14 mm Pan Hd Thread Forming Screw, T25 Drive (Not Shown) Insulation Disc (Warning: Contains RCF, Not Shown) Air Vent Valve Water Temp Sensor High Limit Wire Harness (Not Shown) (Quantity) Part Number ALP080 ALP105 ALP150 101520-01 101521-01 101522-01 101523-01 101710-01 101711-01 101712-01 101713-01 101717-01 101718-01...

  • Page 93

    Gas Train Assembly (Key No’s 24 thru 29) Blower Blower Inlet Shroud Assembly Blower Outlet Gasket Blower Mounting Plate Gas Valve Gas Valve Harness with Plug (Quantity) Part Number ALP080 ALP105 ALP150 101585-01 101585-02 101585-03 101527-01 101528-01 101704-01 101704-02 101345-01 101703-01...

  • Page 94

    Air Pressure Switch Air Pressure Switch Hose Rubber Grommet, Condensate Trap Condensate Trap, Blow Molded Spring Clip, Condensate Trap Blocked Condensate Drain Switch Condensate Comp. Fitting (Quantity) Part Number ALP080 ALP105 ALP150 80160762 7016039 101595-01 101239-01 (2) 101632-01 101587-01 101546-01...

  • Page 95

    MCBA (programmed - 0-2000’ or 0-7000’) MCBA (programmed - 2001 - 7000’) MCBA Transformer MCBA Display Board MCBA Display Board Cable Label, MCBA Display MCBA Display Spacer (Quantity) Part Number ALP080 ALP105 ALP150 101454-01 101230-01 101219-01 101866-01 101866-02 101866-03 101866-08 101866-09 101866-10...

  • Page 96

    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 Gasket, Header, Duo Size (Quantity) Part Number ALP080 ALP105 ALP150 820SOL0001 101217-01 101217-02 101217-03 101227-01 101037-01 101215-01...

  • Page 97

    Description Flue Temp Sensor Wire Harness (Not Shown) Concentric Vent Collar with Viton Cap Vent Terminal Kit (Quantity) Part Number ALP080 ALP105 ALP150 ALP210 101687-01 101454-01 101598-01 101808-01 ALP285 ALP399 101599-01 101809-01...

  • Page 98

    MiSCELLanEOUS PaRTS CaRTOn Temperature/Pressure Gauge External Gas Shut Off Valve Relief Valve Boiler Drain Valve Boiler Stacking Brackets Boiler Stacking Bracket Screws Outdoor Temperature Sensor (Quantity) Part Number ALP080 ALP105 ALP150 101777-01 8056169 806SOL0005 81660363 806603061 (4) 101679-01 (12) 80860743 (1) 101639-01...

  • Page 99

    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.

  • Page 100

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

This manual also for:

Alp210, Alp080, Alp150, Alp285, Alp399

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