Burnham ALPINE Installation, Operation And Service Instructions
  1. Manuals
  2. Brands
  3. Burnham Manuals
  4. Boiler
  5. Alpine Series
  6. Installation, operation and service instructions

Burnham ALPINE Installation, Operation And Service Instructions

Alpine series condensing high efficiency direct vent gas - fired hot water boiler
Hide thumbs Also See for ALPINE:
Table of Contents

Advertisement

Quick Links

N I
S
T
S
E
C
O
N
G
A
S
As an ENERGY STAR
®
guidelines for energy efficiency established by the United States Environmental Protection Agency (EPA).
®
ENERGY 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.
101602-01R9-9/10
A
L
L
A
I T
O
R
V
C I
E
N I
A
L
D
E
N
S
N I
D
R I
-
I F
R
E
D
Partner, Burnham by U.S. Boiler Company has determined that the Alpine™ Series meets the
N
,
O
P
E
R
S
T
R
U
C
I T
P
N I
E
™
G
H
I
G
H
E
E
C
T
V
E
N
H
O
T
W
A
A
T
N I
G
A
O
N
S
F
O
F
F
C I
E I
N
T
T
E
R
B
O
L I
N
D
R
C
Y
E
R
9700609
Price - $5.00

Advertisement

Table of Contents
loading

Related Manuals for Burnham ALPINE

Summary of Contents for Burnham ALPINE

  • Page 1 ™ 9700609 As an ENERGY STAR ® Partner, Burnham by U.S. Boiler Company has determined that the Alpine™ Series meets the guidelines for energy efficiency established by the United States Environmental Protection Agency (EPA). ® ENERGY 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/pl_products/pb_pre_form.asp for the latest Approval Code or ask your local Sales Representative.
  • Page 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 satisfied: 1.
  • Page 4 WaRning This boiler requires regular maintenance and service to operate safely. Follow the instructions contained in this manual. improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Read and understand the entire manual before attempting installation, start-up operation, or service.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Product Description, Specifications and Dimensional Data...... Pre-Installation & Boiler Mounting ............13 Unpacking Boiler..................17 III. Venting...................... A. General Guidelines................18 B. CPVC/PVC Venting................21 C. Stainless Steel Venting................ 29 D. Concentric Polypropylene..............31 E. Removing the Existing Boiler............... 38 Condensate Disposal.................

  • Page 6: Product Description, Specifications And Dimensional Data

    I. Product Description, Specifications and Dimensional Data Alpine™ Series boilers are condensing high efficiency ASME Boiler and Pressure Vessel Code, which provide a gas-fired direct vent hot water boilers designed for use maximum heat transfer and simultaneous protection against flue gas product corrosion. These boilers are not designed...
  • Page 11 I. Product Description, Specifications and Dimensional Data (continued) Table 2a: Rating Data - Models aLP080 thru aLP500 (0 to 2000 Feet Elevation above Sea Level) alpine Series gas-Fired Boilers Input Heat Transfer Net I=B=R Thermal Boiler Water ** Output (MBH)
  • Page 12 I. Product Description, Specifications and Dimensional Data (continued) Table 2C: Rating Data - Models aLP150 thru aLP285 (001 to 10,000 Feet Elevation above Sea Level) alpine Series gas-Fired Boilers Input Net I=B=R Thermal Boiler Water ** Output (MBH) Model AFUE...

  • Page 13: Pre-Installation & Boiler Mounting

    Fuel Gas Code, NFPA 54/ANSI Z223.1, and/or CAN/ CSA B149.1 Installation Codes. 1. Alpine boilers are intended for installations in an area with a floor drain, or, in a suitable drain pan to Appliance is design certified for installation on combustible flooring.
  • Page 14 2 x 4’s anchored to the studs. boiler carton. CaUTiOn CaUTiOn alpine boiler approximate dry weights: The outer edges of the template represent aLP080W – 98 lbs; aLP105W – 112 lbs; minimum side, top and bottom clearances to aLP150W – 16 lbs: aLP210W – 150 lbs combustible material.
  • Page 15 ii. Pre-installation & Boiler Mounting (continued) Figure 2a: Clearances To Combustible and non-combustible Material, Floor Standing Figure 2B: Clearances To Combustible and non-combustible Material, Wall Mounted...
  • Page 16 ii. Pre-installation & Boiler Mounting (continued) n. Place Access Panel Gasket adhesive side p. See Section IV Venting; paragraph “Field (protective paper) down onto Access Panel Installation of CPVC Vent Pipe - Wall Mounted underside and align gasket edges flush with panel Boiler Builds”...

  • Page 17: Unpacking Boiler

    ii. Pre-installation & Boiler Mounting (continued) Figure 2D: Bottom Mounting Bracket installation / Boiler Wall Mounting Figure 2E: access Panel and gasket installation iii. Unpacking Boiler Remove boiler from cardboard positioning sleeve on CaUTiOn shipping skid. Do not drop boiler. WaRning Move boiler to approximate installed position.

  • Page 18: Venting

    2. The Alpine™ is designed to be installed as a between the inner and outer pipes. Refer to Part Direct Vent (sealed combustion) boiler. The air D for specific details.
  • Page 19 iV. Venting (continued) Table : Vent/Combustion air System Options Approved Direct Vent Component Description Boiler Build Orientation Termination Figures Part Vent System Material Table The system includes separate CPVC vent pipe and PVC air intake pipe terminating thru sidewall with Standard 4 thru 9 (thru sidewall)
  • Page 20 iV. Venting (continued) to prevent nuisance boiler shutdowns. However, • Air intake terminal must not terminate in areas boiler may be installed with vertical venting that might contain combustion air contaminates, and sidewall combustion air inlet or visa versa, such as near swimming pools. if installation conditions do not allow alternate •...

  • Page 21: Cpvc/Pvc Venting

    iV. Venting (continued) CPVC/PVC Venting WaRning WaRning When using the CPVC/PVC vent options, the use of CPVC is required when venting in vertical or all CPVC vent components (supplied with boiler) horizontal chase ways. must be used for near-boiler vent piping before transitioning to Schedule 0 PVC pipe (aSTM 1.
  • Page 22 iV. Venting (continued) Table 4C: CPVC/PVC Vent & Air Intake Components (Installer Provided) required for Optional Horizontal (Snorkel) Termination Quantity Part aLP080 & aLP105 aLP150& aLP210 aLP285 thru aLP500 Vent Components number Horizontal (Snorkel) Horizontal (Snorkel) Horizontal (Snorkel) Termination Termination Termination 3"...
  • Page 23 iV. Venting (continued) OFFSET CHANGE OF DIRECTION (VERTICAL OR HORIZONTAL) LONG RUN OF PIPE LOOP LENGTH RESTRAINT (RESTRICTS MOVEMENT) HANGER (ALLOWS MOVEMENT) LOOP LENGTH OF PIPE DIA. LOOP LENGTH (HORIZONTAL ONLY) STRAIGHT RUN (IN.) (L) (IN.) (TOP VIEW) (FT.) 6" 6"...
  • Page 24 iV. Venting (continued) Table : Vent/Combustion air Pipe Length – Two-Pipe Direct Vent System Options (CPVC/PVC and Stainless Steel/PVC or galvanized Steel) 3” Combustion Air Pipe 4” Combustion Air Pipe 3” Vent Pipe 4” Vent Pipe Boiler (Equivalent Length) (Equivalent Length) (Equivalent Length) (Equivalent Length) Model...
  • Page 25 iV. Venting (continued) 4. Near-Boiler Vent/Combustion Air Piping - Floor Mounted Boiler Builds Refer to Figure 6A and the following Steps: a. All CPVC vent components supplied with boiler inside vent carton (3” or 4” Schedule 40 x 30” long CPVC pipe and 3” or 4” Schedule 80 CPVC 90°...
  • Page 26 iV. Venting (continued) ii. Combustion Air Piping • Do not exceed maximum combustion air length. Refer to Table 7. • Size combustion air wall penetration to allow easy insertion of combustion air piping. • Install Rodent Screen and Combustion Air Terminal (supplied with boiler), see Figure 9 for appropriate configuration.
  • Page 27 iV. Venting (continued) Figure 11: Direct Vent - Vertical Terminations Figure 10: Direct Vent - Optional Sidewall Vent Piping Snorkel Terminations • Install fire stops where vent passes through floors, ceilings or framed walls. • Install maximum vertical run of seven (7) The fire stop must close the opening feet of Schedule 40 PVC vent pipe.
  • Page 28 iV. Venting (continued) Figure 12: 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. allow additional vertical (‘X’) distance for expected snow accumulation.

  • Page 29: Stainless Steel Venting

    iV. Venting (continued) Stainless Steel Venting a. Push the stainless steel vent adapter onto the CPVC/PVC connector with a slight twisting CaUTiOn motion. Make sure that the stainless steel vent adapter is inserted at least 1” (refer to Figure 13). Vent systems made by Heat Fab, Protech and Z-Flex rely on gaskets or proper sealing.
  • Page 30 iV. Venting (continued) • Male end of terminal will fit into the ii. Combustion Air Termination female end of any of the approved • Horizontal intake terminal is a tee in the stainless vent systems. upright position. Tee should protrude •...

  • Page 31: Concentric Polypropylene

    iV. Venting (continued) Concentric Polypropylene Venting • Install Rodent Screen (not supplied) and horizontal vent terminal. 1. Vent Length Restrictions • Brace exterior piping if required. a. Vent length restrictions are based on equivalent Vertical Vent Termination length of vent pipe i.e. total length of straight pipe plus equivalent length of fittings.
  • Page 32 iV. Venting (continued) Figure 1: Field installation of Boiler Concentric Vent Collar Field Installation of Boiler Concentric Vent Collar a. Locate and remove six mounting screws from the Miscellaneous Parts Carton. b. Position the Collar onto jacket combination rear/bottom panel and insert collar inner stainless steel vent pipe into the heat exchanger vent Figure 15: Cut-To-Length Extension (Cuttable) outlet.
  • Page 33 iV. Venting (continued) Figure 1: Cutting Straight Pipe iv. Make an insertion mark 1” from the male the drill bit does not penetrate more than end of the outer pipe. 3/8” into the outer pipe. Do not use a Cut the plastic inner pipe so that it will sheet metal screw longer than 1/2”...
  • Page 34 iV. Venting (continued) iii. For horizontal (sidewall) installation, the iv. Use locking bands (provided with all fittings) to secure non-cuttable pipe, as well Horizontal (Wall) Terminal will extend as fittings, to the boiler collar (see Figure past outer wall surface by 4¼” (80/125 mm) or 5½”...
  • Page 35 iV. Venting (continued) Figure 22: Cutting Vent Terminal Pipe • Re-install locking band clamp onto the CaUTiOn joint to secure the terminal to the collar or Exterior wall surface must be reasonably flat to the last section of the vent pipe. attach the Outside Wall Plate.
  • Page 36 iV. Venting (continued) Figure 2: Completing Horizontal (Wall Terminal installation) Figure 2: Vertical Concentric Vent installation • Install the roof flashing using standard • Cut the outer pipe only at the point practice on the roofing system of the marked in Step (e) using aviation shears, structure.
  • Page 37 iV. Venting (continued) Figure 25: Dimension "H" Figure 26: Cutting Vertical Terminal • Slip the terminal section through the roof from the outside. Push into the last section of vent pipe until the mark made in Step (h) is not longer visible. Secure the terminal to the last piece of pipe with three #10 x 1/2”...

  • Page 38: Removing The Existing Boiler

    iV. Venting (continued) Figure 28: Chimney Chase installation Turn on any exhaust fans, such as range-hoods and Removing the Existing Boiler bathroom exhausts, so they will operate at maximum For installations not involving the replacement of an speed. Do not operate a summer exhaust fan. Close existing boiler, proceed to Step B.

  • Page 39: Condensate Disposal

    V. Condensate Disposal 6. If any additional condensate drain line is needed, Condensate Trap and Drain Line. construct the extension from PVC or CPVC 1. All condensate, which forms in the boiler or vent Schedule 40 pipe. The factory supplied ¾” x 5-5/8” system, collects in the sump under heat exchanger long PVC coupling, located in the Part Carton, must and leaves the boiler through factory installed...
  • Page 40 V. Condensate Disposal (continued) Figure 29: Condensate Trap and Drain Line...

  • Page 41: Water Piping And Trim

    1. Relief Valve Piping, ALP080 thru ALP285 Boiler Components Models Alpine (ALP) boilers have factory supplied a. Locate and remove ¾” NPT x close black nipple, Miscellaneous Part Carton (P/N 102942-01 – ALP080 ¾” NPT black tee, ¾” MPT x ¾” FPT Pressure thru ALP210;...
  • Page 42 Piping System To Be Employed. plane and parallel to boiler side. Alpine (ALP) boilers are designed to operate in a closed c. Install the second close nipple into tee run top loop pressurized system. Minimum pressure in the outlet.
  • Page 43 Notes: Required Flow (GPM) = ** Output (MBH) x 1000/500 x 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. Alpine Boiler Head Loss vs. Flow Flow Rate (GPM)
  • Page 44 Vi. Water Piping and Trim (continued) Table 12: Recommended Circulator Models for alpine (aLP) Boilers Based on 25°F Temperature Differential and Up to 75 ft. Equivalent Length Near-Boiler Piping - Space Heating Circulator Near-Boiler Near-Boiler Flow, GPM Boiler Supply Boiler Return...
  • Page 45 The alpine (aLP) boiler heat exchanger is made from stainless steel tubular coil having relatively narrow waterways. Once filled with water, it will be subject to the effects of corrosion. Failure to take the following precautions to minimize corrosion and heat exchanger waterways overheating could result in severe boiler damage.
  • Page 48 Special Situation Piping Installation Requirements circulators will be required to properly install a Observe the following guidelines when making the Alpine™ Series boiler. See Paragraph B above for actual installation of the boiler piping for special information on sizing the circulators.
  • Page 49 Vi. Water Piping and Trim (continued) Figure : isolation of the Boiler From Oxygenated Water with a Plate Heat Exchanger...

  • Page 50: Gas Piping

    Vii. gas Piping 2. Maximum gas demand. Refer to the boiler’s input as WaRning printed on its rating label. Also consider existing and expected future gas utilization equipment (i.e. water Failure to properly pipe gas supply to boiler may heater, cooking equipment). result in improper operation and damage to the 3.
  • Page 51 Vii. gas Piping (continued) WaRning WaRning Failure to use proper thread compounds on all gas supply to boiler and system must be gas connectors may result in leaks of flammable absolutely shut off prior to installing or servicing gas. boiler gas piping. 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.;...
  • Page 52 Refer to National Figure a: Recommended gas Piping Electrical Code, NFPA 70. Pressure test. See Table 17 for Alpine Min./Max. Pressure Ratings. The boiler and its gas connection must be leak tested before placing boiler in operation.
  • Page 53 3. The gas pressure can be measured at the gas valve inlet pressure port. Refer to Figure 34B. Alpine Model 500 only (if equipped with optional low 4. If either pressure switch is tripped, it must be and high gas pressure switches): manually reset before the boiler can be restarted.

  • Page 54: Electrical

    Viii. Electrical DangER Positively assure all electrical connections are unpowered before attempting installation or service of electrical components or connections of the boiler or building. Lock out all electrical boxes with padlock once power is turned off. WaRning Failure to properly wire electrical connections to the boiler may result in serious physical harm. Electrical power may be from more than one source.
  • Page 55 Viii. Electrical (continued) Low Voltage (24 VAC) Connections - see Figure 35. WaRning 3. The terminal block TB-2 in conjunction with terminal screw identification label is attached to When making low voltage connections, make the junction box front and located inside Sage2.1 sure that no external power source is present Control compartment on the left side.
  • Page 58 Viii. Electrical (continued) Figure 6: Ladder Diagram...
  • Page 59 Viii. Electrical (continued) 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 61: Boiler Stacking

    • The remaining lower bracket hole must align and/or domestic hot water heating loads, where employing with a matching bottom boiler left side panel top two (2) Alpine (ALP) boilers will offer the benefits of positioning dimple. greater operational efficiency, floor space savings and boiler •...
  • Page 62 iX. Boiler Stacking (continued) permissible, providing common pipe has sufficient 3. Water Piping and Trim - Follow instructions in flow capacity to handle combined condensate Section VI “Water Piping and Trim” of the manual volume of stackable combination. for system piping and boiler secondary piping 2.

  • Page 63: Modular Installation

    X. Modular installation General Guidelines The minimum horizontal distance between any adjacent individual module (boiler) roof vent 1. Read and follow all venting, combustion air, terminations is one (1) foot. water piping, gas piping and electrical instructions contained in this manual, unless otherwise instructed 2.

  • Page 66: Water Piping And Trim

    Chimney chase concentric venting is permitted an indirect water heater circulator, compare the for modules, when stackable, providing specified flow range through an Alpine model boiler concentric vertical (roof) vent terminals, if level to an indirect water heater (Alliance SL™) model...

  • Page 76: Electrical

    X. Modular installation (continued) Each individual module (boiler) must be provided with own WaRning fused disconnect and own service switch. Install modular boiler wiring in accordance with requirements of if gas pressure in the building is above ½ psig, an additional gas pressure regulator is required. authority having jurisdiction.

  • Page 77: Modular Boiler Operating Information

    X. Modular installation (continued) Modular Boiler Operating Information 1. Major Features a. “Plug & Go” Multiple Boiler Control Sequencer e. Customized Sequences When multiple boilers are installed, the Sage2.1’s Normally, boilers are started and stopped in Sequencer may be used to coordinate and numerical order.
  • Page 78 X. Modular installation (continued) k. Advanced Boiler Sequencing After there is a Call For Heat input, both header water temperature and boiler firing rate percent are used to start and stop the networked boilers. The control starts and stops boilers when the water temperature is outside the user selected “Diff Above”...

  • Page 79: Operating Modes

    X. Modular installation (continued) . Modular Boiler Operating Information (continued) Select “Status” button on home screen (when sequencer 2. Operating Mode Master is enabled) to view: a. Sequencer Status Screen The “Sequencer Status” screen, shown in Figure 46, appears on the Sage2.1 Controller when the Sequence Master is enabled and the “Home”...
  • Page 80 X. Modular installation (continued) . Modular Boiler Operating Information (continued) 2. Operating Mode (continued) b. Networked Boilers Detail Screens The “Networked Boilers” detail screen, shown in Figure 47, is available on the Sage2.1 Controller when the Sequence Master is enabled and the “Home”...

  • Page 81: Required Equipment And Setup

    X. Modular installation (continued) . Modular Boiler Operating Information (continued) 3. Required Equipment and Setup a. Header Sensor (p/n 103104-01) A header sensor must be installed and wired to the Master Sequencer “enabled” Sage2.1 Controller. The header sensor is installed on the common system piping and provides blended temperature information to the Sequence Master.
  • Page 82 X. Modular installation (continued) . Modular Boiler Operating Information (continued) 3. Required Equipment and Setup d. Modular Boiler Setup Step Description Comments Wire the header sensor to low voltage terminal strip terminals “Header sensor”. Install and wire the Header nOTE This step can not be skipped.

  • Page 83: Adjusting Parameters

    X. Modular installation (continued) . Modular Boiler Operating Information (continued) 4. Adjusting Parameters From the “Home” screen select the Adjust button to access the adjust mode screens links (if required refer to “Entering Adjustment Mode”, Section XII, Paragraph D, 4 for login in instructions). Sequencer Master “Press”...
  • Page 84 X. Modular installation (continued) . Modular Boiler Operating Information (continued) 4. Adjusting Parameters (continued) Pump “Press” button to access the following parameters: Setup Factory Range / Parameter and Description Setting Choices System Pump run pump for: Activates the system pump output according to selected function. Never, Never: Pump is disabled and not shown on status screen...
  • Page 85 X. Modular installation (continued) . Modular Boiler Operating Information (continued) 4. Adjusting Parameters (continued) Example Pump Parameter selections (continued): b. Multiple boilers IWH Piped to Primary, Optional Domestic Hot Water Priority Sequencer Master Boiler 2 (Boiler 1) Wiring locations: Thermostat DHW call for heat System pump DHW pump...

  • Page 86: System Start-Up

    Xi. System Start-up Verify that the venting, water piping, gas piping and 2. Alpine gas valves have inlet and outlet pressure electrical system are installed properly. Refer to taps with built-in shut off screw. Turn each installation instructions contained in this manual.
  • Page 87 WaRning normal. Check Gas Inlet Pressure Each alpine Series boiler is tested at the factory Check the inlet pressure and adjust if necessary. Verify and adjustments to the air fuel mixture are normally not necessary. improper gas valve or...
  • Page 88 Xi. System Start-up (continued) Alpine™ Series Lighting and Operating Instructions Figure 51: Lighting instructions...
  • Page 89 Adjust Supply Water Temperature 1. All Alpine boiler models can be converted from As shipped, the heating and indirect water heater set Natural Gas to LP Gas. point supply temperatures are both set to 180°F. If necessary, adjust these to the appropriate settings for 2.
  • Page 90 Xi. System Start-up (continued) 4. Before attempting to start the boiler, make the number of turns to the throttle screw called for in Table 24. 5. Attempt to start the boiler using the lighting instructions located inside the lower front cover of the boiler.
  • Page 91 Xi. System Start-up (continued) 7. Perform a combustion test. Refer to Paragraph K • To increase the CO (reduce the O ) turn the above for details. throttle counter-clockwise 8. While the burner is at high fire adjust the throttle as Make adjustments in increments of 1/8 to 1/4 turn and allow the boiler at least a minute to respond to needed to obtain the CO...

  • Page 92: Operation

    Xii. Operation Major Features 1. General 5. Advanced Touch Screen Display The Sage2.1™ Control provides safety interlocks and water temperature control. The Sage2.1 simply controls boiler modulation and pump outputs based on the boiler water outlet temperature and a contractor adjusted setpoint.
  • Page 93 Xii. Operation (continued) 7. Priority Demand b. Domestic Hot Water The Sage2.1 accepts a call for heat (demand) from A domestic hot water demand is received by wiring multiple places and responds to each demand according a demand contact to the low voltage terminal to it’s relative importance.
  • Page 94 Xii. Operation (continued) Major Features (continued) increases. When the water temperature is 8. Boiler Temperature Regulation properly matched to home heating needs there a. Overview is minimal chance of room air temperature Based on the call for heat type, the Sage2.1 overshoot.
  • Page 95 Xii. Operation (continued) Major Features (continued) 9. Boiler Protection Features reset Hard Lockout is set. This condition is the result of incorrectly attaching the supply and return a. Supply Water Temperature High Limit piping. The boiler is equipped with independent automatic d.

  • Page 96: Operating Mode

    Xii. Operation (continued) Operating Mode 1. Home Screen Under normal conditions, the boiler display shows the “Home” screen and the display looks like that shown in Figure 54. The temperature value shown is the boiler’s supply temperature. Boiler status is shown below the supply water temperature.

  • Page 97: Boiler Status Screen

    Xii. Operation (continued) Operating Mode (continued) 2. Boiler Status Screen Select “Status” button on home screen to view: Fault The “Status” screen, shown in Figure 55, provides Indication & Boiler 1 an overview of boiler operation. The following Active Screen Link Supply 180 information is provided on this screen: Fault...

  • Page 98: Controls Start-Up Checklist

    Xii. Operation (continued) Controls Startup Check List The Sage2.1 Control is factory programmed with default parameters. Before operating the boiler, these parameters must be checked and adjusted as necessary to conform to the site requirements. Follow the steps below, making selections and adjustments as necessary to ensure optimal boiler operation.

  • Page 99: User Interface

    Xii. Operation (continued) User Interface 1. Using The Display The Sage2.1 uses a state-of-the-art touch screen display. The following is a display arrangement overview: Figure 56: Display arrangement Overview Note: The “Home Screen” is the default screen. Any screen left untouched for more than four minutes will revert to the home screen.

  • Page 100: Help Screens

    Xii. Operation (continued) (continued) User Interface 3. Help Screens Limit String Status Display The “Help” screen provides access to active faults, lockout history, the service contact and the boiler This display is provided to identify the cause of an reset button. The “Help” screen is accessed from Interlock input “open”...

  • Page 101: Entering Adjust Mode

    Xii. Operation (continued) User Interface (continued) Adjust Mode 4. Entering Adjust Mode Warning! Only Qualified Technicians Should Adjust The “Adjust mode” screen is accessed from the Controls, Contact Your “Home” screen. The “Adjust Mode” provides For Service Contact: Qualified Heating Professional contractors access to view and adjust additional CONTRACTOR NAME ADDRESS...

  • Page 102: Adjusting Parameters

    Xii. Operation (continued) Adjusting Parameters From the “Home” screen select the Adjust button to access the adjustment mode screens show below (if required, refer to the previous page to review how to enter Adjustment mode): System Modulation Setup Setup Pump Contractor The following pages describe Setup...
  • Page 103 Xii. Operation (continued) Adjusting Parameters (continued) Modulation “Press” button to access the following parameters: Setup Factory Range / Parameter and Description Setting Choices Boiler Type The Boiler Type parameter changes the parameters listed in Table 30. Factory level password is required. This See Table 30 See Table 30 parameter is intended to allow a user to set the parameters in a spare part Sage2.1 to a particular boiler type.
  • Page 104 Xii. Operation (continued) Adjusting Parameters (continued) Pump “Press” button to access the following parameters: Setup Factory Setting Range / Choices Parameter and Description System Pump run pump for: Activates the system pump output according to selected function. Never: Pump is disabled and not shown on status screen. Any Demand: Pump Runs during any call for heat.
  • Page 105 Xii. Operation (continued) Adjusting Parameters (continued) Example Pump Parameter selections: a. Single boiler with no Indirect Water Heater Parameter Selections: System Pump= “any demand” Boiler Pump = “any demand” System Circulator(s) To System DHW Pump = “never” Boiler Circulator Explanation: This piping arrangement only services central heat.
  • Page 106 Xii. Operation (continued) Adjusting Parameters (continued) Central Heat “Press” button to access the following parameters: Factory Range / Parameter and Description Setting Choices Central Heat Setpoint 180°F 80°F to 190°F Target temperature for the central heat priority. Value also used by the outdoor air reset function. Central Heat Thermostat “Sleep”...
  • Page 107 Xii. Operation (continued) Adjusting Parameters (continued) Outdoor Reset “Press” button to access the following parameters: Factory Range / Parameter and Description Setting Choices Outdoor Reset Enable If an outdoor sensor is installed and Outdoor Reset is Enabled, the boiler will automatically adjust the heating zone set point temperature based on the outdoor reset curve in Figure 57.
  • Page 108 Xii. Operation (continued) Adjusting Parameters (continued) Figure 5: Outdoor Reset Curve Central Heat Central Heat Heating Element Type Heating Element Type Setpoint Setpoint in Slab Radiant High 180 to 190°F Fan Coil 100 to 10°F Mass Radiant Convection Baseboard Staple-up Radiant 160 to 190°F 10 to 160°F Fin Tube...
  • Page 109 Xii. Operation (continued) Adjusting Parameters (continued) Remote “Press” button to access the following parameters: 4-20mA Factory Range / Parameter and Description Setting Choices Central Heat Modulation Source This parameter enables the 4-20mA input to control firing rate and the thermostat input to control Local, boiler on/off demand directly without using internal setpoint.

  • Page 110: Service And Maintenance

    Xiii. Service and Maintenance DangER This boiler uses flammable gas, high voltage electricity, moving parts, and very hot water under high pressure. assure that all gas and electric power supplies are off and that the water temperature is cool before attempting any disassembly or service. Do not attempt any service work if gas is present in the air in the vicinity of the boiler.
  • Page 111 Drain and flush the inside of the heat exchanger a. The following heating system freeze protection and condensate collector. Do not use any cleaning products are recommended for Alpine boilers: agents or solvents. Re-install insulation disc. Fernox™ Protector Alphi 11 (combined 9.
  • Page 112 Xiii. Service and Maintenance (continued) b. Equivalent system freeze protection products c. Using pliers, release spring clip securing the overflow switch to condensate trap body and may be used in lieu of product referenced above. In general, freeze protection for new or remove the switch.
  • Page 113 Xiii. Service and Maintenance (continued) e. Using pliers, release spring clip securing the Orientation” for details. Insure that pressure overflow switch to condensate trap body and switch hose is reconnected to the trap. remove the switch. Note that the switch has k.

  • Page 114: Troubleshooting

    XiV. Troubleshooting WaRning Turn off power to boiler before working on wiring. Troubleshooting problems where no error code is displayed. Condition Possible Cause Display Blank, Fan off, LWCO lights off, no green No 120VAC Power at boiler. Check breaker and wiring between breaker panel and boiler. power light on Sage2.1 Controller •...

  • Page 115: Soft Lockout Codes

    XiV. Troubleshooting (continued) the “Help” button will “blink”. Select the “blinking” Troubleshooting problems where a Soft Lockout Code is displayed. When a soft lockout occurs, the “Help” button to determine the cause of the soft lockout. The boiler will automatically restart once the boiler will shut down, the display will turn red and condition that caused the lockout is corrected.

  • Page 116: Hard Lockout Codes

    XiV. Troubleshooting (continued) “Help” button to determine the cause of the Hard Troubleshooting problems where a Hard Lockout Code is displayed. When a hard lockout occurs, the Lockout. Once the condition that caused the lockout is corrected, the boiler will need to be manually reset boiler will shut down, the display will turn red and using the Reset button on the “Active Fault”...

  • Page 117: Repair Parts

    XV. Repair Parts All Alpine™ Series Repair Parts may be obtained through your local U.S. Boiler Wholesale distributor. Should you require assistance in locating a U.S. Boiler distributor in your area, or have questions regarding the availability of U.S. Boiler products or repair parts, please contact U.S. Boiler Customer Service at (717) 481-8400 or Fax (717) 481-8408.
  • Page 118 XV. Repair Parts (continued) (Quantity) Part Number Description ALP080 ALP105 ALP150 ALP210 ALP285 ALP399 ALP500 MCBA Control 101585-01 101585-02 101585-03 101585-04 101585-05 101585-06 101585-07 Gas Train Assembly (Key No’s 23 thru 29) Sage2.1 Control 102852-01 102852-02 102852-03 102852-04 102852-05 102852-06 102852-07 Gas Valve Flange Kit 102972-03...
  • Page 119 XV. Repair Parts (continued) (Quantity) Part Number Description ALP080 ALP105 ALP150 ALP210 ALP285 ALP399 ALP500 Air Pressure Switch 80160762 101862-01 Air Pressure Switch Hose 7016039 7016046 Rubber Grommet, Condensate Trap 101595-01 Condensate Trap, Blow Molded 101239-01 (2) 101632-01 Spring Clip, Condensate Trap Blocked Condensate Drain Switch 101587-01 Condensate Comp.
  • Page 120 XV. Repair Parts (continued) (Quantity) Part Number Description ALP080 ALP105 ALP150 ALP210 ALP285 ALP399 ALP500 Wiring Harness (Not Shown) 102701-01 Control Panel Assembly (Programmed - 103142-01 103142-02 103142-03 103142-04 103142-05 103142-06 103142-07 0-2000’ or 0-7000’) (Includes all parts shown) Control Panel Assembly (Programmed - 103142-08 103142-09 103142-10 103142-11 2000’...
  • Page 121 XV. Repair Parts (continued) (Quantity) Part Number Description ALP080 ALP105 ALP150 ALP210 ALP285 ALP399 ALP500 Rubber Grommet, Gas Line 820SOL0001 101638-01 Jacket, Rear/Bottom Panel 101217-01 101217-02 101217-03 101217-04 101764-01 101764-02 102608-01 Lower Front Door Assembly 101227-01 101227-02 101227-01 Draw Latch 101037-01 Jacket, Left Side Panel 102776-01...
  • Page 122 XV. Repair Parts (continued) Quantity Part Vent System Components ALP080 & ALP150 & Number ALP285 thru ALP500 ALP105 ALP210 3” Schedule 40 PVC Tee Vent/Combustion 102190-01 Air Terminal 4” Schedule 40 PVC Tee Vent/Combustion 102190-02 Air Terminal 3” Stainless Steel Rodent Screens 102191-01 4”...
  • Page 123 XV. Repair Parts (continued) (Quantity) Part Number Description ALP080 ALP105 ALP150 ALP210 ALP285 ALP399 ALP500 MiSCELLanEOUS PaRTS CaRTOn 102942-01 102942-02 102942-03 Temperature/Pressure Gauge 100282-01 External Gas Shut Off Valve 806SOL0005 101615-01 Relief Valve 81660363 81660302 Boiler Drain Valve 806603061 Boiler Stacking Brackets (2) 101679-01 Boiler Stacking Bracket Screws (8) 80860743...
  • Page 124 XV. Repair Parts (continued) (Quantity) Part Number Description ALP080 ALP105 ALP150 ALP210 ALP285 ALP399 ALP500 Vent Elbow w/Flue Sensor Port 102878-01 Rear Air Box 102867-01 Bottom Securing Bracket 102870-01 Hanging Bracket, Boiler 102868-01 Hanging Bracket, Wall 102869-01 Air Collar Plate Assembly 102871-01 Air Collar Plate Gasket 102876-01...
  • Page 125 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 126: Appendix B - Figures

    appendix a - Figures Figure Page Description number number Section I - Product Description, Specifications & Dimensional Data Models ALP080 thru ALP210 (Floor Mounted) Figure 1A Models ALP080 thru ALP210 (Wall Mounted) Figure 1B Models ALP285 thru ALP399 (Floor Mounted Only) Figure 1C Figure 1D Model ALP500 (Floor Mounted Only)
  • Page 127 appendix a - Figures (continued) Figure Page Description number number SectionV - Condensate Disposal Condensate Trap and Drain Line Figure 29 Section V - Water Piping and Trim Factory Supplied Piping & Trim Installation Figure 30 Near Boiler Piping - Heating Only (with Central Heating Circulators) Figure 31 Near Boiler Piping - Heating Plus Indirect Water Heater Figure 32...
  • Page 128 appendix a - Figures (continued) Figure Page Description number number Section Xi - System Start-Up Lighting Instructions Figure 51 Figure 52 Burner Flame Dungs Gas Valve Detail Figure 53 Section Xii - Operation Home Screen Figure 54 Status Screen Figure 55 Display Arrangement Overview Figure 56 Outdoor Reset Curve...

  • Page 129: Appendix C - Tables

    Section X - Modular installation Table 20 Modular Boiler Water Manifold Sizing Recommended Circulator Models for Alpine (ALP) Boilers and Alliance SL Indirect Water Heaters Installed as Part of Near-Boiler Piping Up to 75 Ft. Equivalent Length - Indirect Water Heater Table 21 71 &...
  • Page 130 appendix B - Tables (continued) Table Page Description number number Section Xi - System Start-Up Recommended Combustion Settings, Natural Gas Table 23 Number of Clockwise Throttle Screw Turns for LP Conversions Table 24 Recommended Combustion Settings, LP Gas Table 25 Section Xii - Operation Table 26 Order of Priority...

  • Page 131: Service Record

    SERViCE RECORD DATE SERVICE PERFORMED...

  • Page 132: Warranty

    Boiler Company, Inc. with respect to any defect in a residential grade boiler, parts, ® date of original installation. In the event that any cast iron section of a Burnham or accessories and U.S. Boiler Company, Inc. shall have no express obligations, ™...

This manual is also suitable for:

Alp080Alp105Alp150Alp210Alp285Alp399 ... Show all

Table of Contents