Boiler Company Burnham Hydronics Alpine ALP080 Installation, Operating And Service Instructions
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Boiler Company Burnham Hydronics Alpine ALP080 Installation, Operating And Service Instructions

Condensing high efficiency direct vent gas - fired hot water boiler
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As an ENERGY STAR
Partner, Burnham Hydronics has determined that the Alpine™ Series meets the ENERGY
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STAR
guidelines for energy efficiency 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 qualified installer, service agency or the
gas supplier. This boiler requires a special venting system. Read these instructions carefully before installing.
101602-01-2/08
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Price - $5.00

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  • Page 1 ™ As an ENERGY STAR Partner, Burnham Hydronics has determined that the Alpine™ Series meets the ENERGY ® STAR guidelines for energy efficiency 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.
  • Page 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.
  • Page 3 f i l l i t . r i l l i t i l t t i i l i...

  • Page 4: Table Of Contents

    Table of Contents I. Product Description, Specifications VIII. Electrical ........38 and Dimensional Data....4 IX. Boiler Stacking ......43 II. Pre-Installation ....... 8 X. System Start-up ......45 III. Unpacking Boiler ......9 XI. Operation ........51 IV. Venting ........... 9 XII. Service and Maintenance ....63 V. Condensate Disposal ....22 XIII. Troubleshooting ......67 VI. Water Piping and Trim ....
  • Page 7 Table 2A: Rating Data - Models ALP080 thru ALP399 (0 to 2000 Feet Elevation Above Sea Level) Alpine Series Gas-Fired Boilers Input Heat Transfer Net I=B=R Thermal Boiler Water * Model ** Output AFUE Combustion (MBH) Area Ratings Efficiency Volume Number (MBH) Efficiency (%)

  • Page 8: Pre-Installation

    ii. Pre-installation 2. Access is provided to the condensate trap located underneath the heat exchanger. Install on level floor. For basement installation provide a solid base such as concrete, if floor is not level or if water may be encountered on floor around boiler. Floor must be able to support weight of boiler, water and all additional system components.

  • Page 9: Unpacking Boiler

    III. Unpacking Boiler Remove boiler from cardboard positioning sleeve on shipping skid. Move boiler to approximate installed position. Remove all crate fasteners. f i l Lift and remove outside container. Move boiler to its permanent location. IV. Venting f i l .
  • Page 10 4. Place in operation the appliance being inspected. hardware - six (6) #8 x ½” black oxide round head Follow the Lighting (or Operating) Instructions. Phillips sheet metal screws - are shipped inside Adjust thermostat so appliance will operate Miscellaneous Part Carton. continuously.
  • Page 11 8. Provide minimum service clearance between boiler General Guidelines back and concentric vent exiting through outside 1. Vent system installation must be in accordance wall, for concentric vent installation/replacement with National Fuel Gas Code, NFPA 54/ANSI and/or flue temperature sensor service/replacement, Z221.3 or applicable provisions of local building as follows: codes.
  • Page 12 Table 6: Vent Length Vent Length Inner/Outer Pipe Boiler Model Concentric Vent Wall Opening Diameter Dia., mm Minimum * Maximum ALP080 ALP105 Factory Supplied 80/125 mm 21-7/8 in 5-1/2 in Horizontal (Wall) Terminal ALP150 Total of 60 Equivalent ft. ALP210 ALP285 Factory Supplied 100/150 mm...
  • Page 14 Table 7: Concentric Vent Components Component Part Number Component Description Size Equivalent Vent Comments Length, Ft 101542-01 90° Elbow – Long Radius 80/125 mm 101908-01 45° Elbow - Long Radius 80/125 mm 101163-01 Cut -To-Length Extension,500 mm (19-1/2”) 80/125 mm 1.63 **Can be cut 101162-01...
  • Page 15 attached Outside Wall Plate and mark the vent) at the planned location of the horizontal Horizontal (Wall) Terminal outer pipe. To terminal. achieve a square cut of the outer pipe, place b. Measure dimension “L” from exterior wall outer several marks around the outer pipe to establish a surface to the end of the last fitting (or end of cut line.
  • Page 16 i. Install the supplied Inside Wall Plate onto the shortened Horizontal (Wall) Terminal interior end and move the plate to cover interior wall cut opening. Secure the plate with provided fasteners, then, apply the sealant around plate Figure 6: Dimension “L” sides to seal it to interior wall.
  • Page 17 Table 8: Cut-To-Length Extensions (Cuttable) Part No. Component Description Size Cut-To-Length Extension, 101163-01 500 mm (19-1/2”) 80/125 mm Cut-To-Length Extension, 101162-01 1000 mm (39”) Cut-To-Length Extension, 101550-01 500 mm (19-1/2”) 100/150 mm Cut-To-Length Extension, 101551-01 1000 mm (39”) Figure 11: Cut-To-Length Extension (Cuttable) b.
  • Page 18 Figure 13: Cutting Straight Pipe 23. To join Concentric Vent Pipe refer to Figure 14 “Joining Cuttable Pipe” and Figure 15 “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 19 24. Vertical (Roof) Terminal Installation. Refer to e. Add 1” to distance “H”. Carefully mark this Figures 17, 18 and 19. length on the pipe as shown in Figure 17. f. Cut the outer pipe only at the point marked in In addition to the vertical terminal, either a Flat Roof Flashing or Sloped Roof Flashing is required Step (e) using aviation shears, a hacksaw, or an...
  • Page 20 25. Chimney Chase Installation. location of the pin, positioned on the back of the support bracket, onto the chimney rear wall. A vertical concentric vent system, either 80/125 mm Drill a 7/16” diameter x 3-1/2” deep hole in the or 100/150 mm can be installed in an UNUSED marked location, then, insert the back bracket pin masonry chimney.
  • Page 21 Figure 19: Chimney Chase Installation...

  • Page 22: 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 thru factory installed...

  • Page 24: Water Piping And Trim

    VI. Water Piping and Trim . ) . – ALP399), which includes supply piping components, gas piping components, Temperature & Pressure Gauge, Pressure Relief Valve and Drain Valve. See Figure 21 “ l l i Factory Supplied Piping and Trim Installation”. Install these components prior to connecting boiler to system piping as follows: 1.
  • Page 25 2. ALP399 Boiler Model NPT black reducing bushing and Temperature & Pressure Gauge. a. Locate and remove (2) ¾” NPT x close black nipples, ¾” NPT black tee, ¾” FPT x ¾” FPT b. Mount the nipple into 1½” boiler supply tapping Pressure Relief Valve, ¾”...
  • Page 26 a. The flow rate thru system must be the same as NOTICE thru boiler and fall within limits specified in Table 9. Where it is not possible to install a separate b. Pressure drop thru entire system must be boiler loop, the system circulator must be known, added to pressure drop thru boiler, and, sized to ensure that the flow through boiler a circulator selected to provide required flow at...
  • Page 31 Table 10 : Recommended Circulator Models for Alpine (ALP) Boilers ALP080 ALP105 ALP150 Piping Loop Equivalent Length, Ft Piping Loop Equivalent Length, Ft Piping Loop Equivalent Length, Ft Temperature Drop DT, °F 50 or Less 51 - 5 50 or Less 51 - 5 50 or Less 51 - 5...
  • Page 32 Table 11: Fitting and Valve Equivalent Length Table 11: Fitting and Valve Equivalent Length (cont’d) Copper Fitting and Sweat Valve Equivalent Length (Ft) Threaded Fitting and Valve Equivalent Length (Ft) Copper Pipe or Valve Size Black Threaded Pipe or Valve Size Fitting or Valve Fitting or Valve Description...
  • Page 33 . Piping Standard Installation Requirements. 5. Automatic Air Vent (Required) -At least one automatic air vent is required. Manual vents will Observe the following guidelines when making the usually be required in other parts of the system to actual installation of the boiler piping: remove air during initial fill.
  • Page 34 3. Boiler Piping with Air Handlers - Where the 2. Piping with a Chiller - If the boiler is used in boiler is connected to air handlers through which conjunction with a chiller, pipe the boiler and chiller in parallel. Use isolation valves to prevent chilled refrigerated air passes, use flow control valves in the water from entering the boiler.

  • Page 35: Gas Piping

    VII. Gas Piping 3. Length of piping and number of fittings. Refer to Tables 12A (natural gas) or 12B (LP gas) for maximum capacity of Schedule 40 pipe. Table 13 lists equivalent pipe length for standard fittings. 4. Specific gravity of gas. Gas piping systems for gas with a specific gravity of 0.60 or less can be sized directly from Tables 12A or 12B, unless authority having jurisdiction specifies a gravity factor be...
  • Page 36 Table 12B: Maximum Capacity of Schedule 40 Black Pipe in CFH* (LP Gas) For Gas Pressures of 0.5 psig or Less Inlet Pressure 11.0 Inch W.C.; 0.3 Inch W.C. Pressure Drop Nominal Pipe Inside Length of Pipe, Ft. Size, In. Diameter, In.
  • Page 37 Table 14: Specific Gravity Correction Factors Pressure test. See Table 15 for Alpine Min./Max. Pressure Ratings. The boiler and its gas connection Specific Correction Specific Correction must be leak tested before placing boiler in operation. Gravity Factor Gravity Factor 1. Protect boiler gas control valve. For all testing over 0.60 1.00 0.90...

  • Page 38: Electrical

    VIII. Electrical . f f service switch such that the boiler can be shut-off General. Install wiring and electrically ground boiler without exposing personnel to danger in the event of in accordance with authority having jurisdiction or, in an emergency. Connect the main power supply and the absence of such requirements, follow the National ground to the three (3) boiler wires (black, white and Electrical Code, NFPA 70, and/or CSA C22.1 Electrical...
  • Page 39 1. Line Voltage (120 VAC) Connections (Figure 27) – The line voltage connections are located in the junction box on the left side of the vestibule: • Black – Line voltage “hot” • White – “Neutral” for boiler and circulators •...
  • Page 40 Figure 27: Wiring Connections Diagram...
  • Page 41 Figure 28: Ladder Diagram...
  • Page 42 Figure 29: Wiring of Isolation Relay for Control of Two Heating Circulators Figure 30: Wiring for MCBA Modulating Boiler Control Time Delay Relay Box 5. If the boiler installation site may be subject to low f. Connect additional field wiring (not included supply voltage conditions or “brownouts”, that in the kit) from MCBA Time Delay Relay Box would affect MCBA Modulating Boiler Control...

  • Page 43: Boiler Stacking

    IX. Boiler Stacking For installations with unusually high space heating bottom positioning dimples are evenly spaced and/or domestic hot water heating loads, where employing from boiler front and back, while side panel top two (2) Alpine (ALP) boilers will offer the benefits of positioning dimples follow specific pattern to greater operational efficiency, floor space savings and boiler compensate for Alpine (ALP) boiler model variable...
  • Page 44 of individual boiler vent termination. Follow 3. Water Piping and Trim - Follow instructions in instructions in Section V for each individual boiler Section VI “Water Piping and Trim” of the manual flue gas condensate line construction and condensate for system piping and boiler secondary piping disposal.

  • Page 45: System Start-Up

    X. System Start-up Verify that the venting, water piping, gas piping and electrical system are installed properly. Refer to installation instructions contained in this manual. Confirm all electrical, water and gas supplies are turned off at the source and that vent is clear of r i f obstructions.
  • Page 46 Alpine™ Series Lighting and Operating Instructions Figure 32: Lighting Instructions...
  • Page 47 Figure 33: Burner Flame Purge Air From Gas Train Perform Combustion Test Upon initial start-up, the gas train will be filled with air. Perform a combustion test. Boilers equipped with a concentric vent system have a flue gas sample tap Even if the gas line has been completely purged of air, it may take several tries for ignition before a flame is located in the boiler vent collar (under the screw cap).
  • Page 48 Table 18: Permitted Conversions Adjust Supply Water Temperature As shipped, the heating and indirect water heater set Fuel Converted Planned Boiler Valve (Dungs) Installation point supply temperatures are both set to 180°F. If Model Size Gas Valve Model Altitude necessary, adjust these to the appropriate settings for From (NPT) Range...
  • Page 49 7. Perform a combustion test. Boilers equipped with a concentric vent system have a flue gas sample tap located in the boiler vent collar (under the screw cap). 8. While the burner is at high fire adjust the throttle as needed to obtain the CO (or O ) settings shown in...
  • Page 50 r " " l l i l l i l l i l l i l l i l l i l l i l l i l l i l i t Table 21: Inlet Pressure Limits • Apply the “Boiler Conversion Label” to a conspicuous surface on, or adjacent to, the outer Inlet Pressure (Inches w.c.) boiler jacket.

  • Page 51: Operation

    XI. Operation I. Factory Preset Boiler Operating Parameters c. “Stby” for Standby Mode. Upon entering standby mode, “Stby” will briefly appear on (See Table 22 for Parameter Descriptions) the display and then the display will show the The Alpine (ALP) boiler uses a microprocessor based boiler’s status along with the supply temperature Honeywell control, known as a “MCBA”, to manage (Figure 35).
  • Page 52 Table 22: Parameter Descriptions Factory Setting Access Parameter Description Code ALP080 ALP105 ALP150 ALP210 ALP285 ALP399 T3set DHW DHW system 1 (On) access Code CH system 1 (On) needed T1top CH Mode T1foot CH Mode T4 minimum T4 maximum T4 frost protection * T4 correction Tblocking Booster time...
  • Page 54 Two basic types of errors codes are shown on the An external limit control can be installed between display: terminals 5 and 6 on the terminal strip. Be sure to remove the jumper between terminals 5 and 6 when 1. Soft Lockout Codes – When a soft lockout occurs, adding an external limit control to the system.
  • Page 55 Additionally, either the keypad or the personal computer can be used to obtain information about the boiler current status and operating history. Adjusting Parameters via Boiler Keypad Entering the Access Code 1. With boiler running, toggle the Mode key until you reach the (STBY) Standby mode.
  • Page 56 Figure 38: Expanded Menu Tree (Cont’d on next page)
  • Page 57 Figure 38: Expanded Menu Tree (cont’d.) Figure 39: Adjusting Boiler Water Reset Curve...
  • Page 58 14; Parameter 13 defines the “thousands” and the target supply temperature is always defined hundreds” places and Parameter 14 defines the by Parameter 4 when the boiler is responding to “tens” and “ones” places. The ignition fan speed a call for central heat, regardless of the outdoor is only adjustable in increments of hundreds, so temperature.
  • Page 59 e. Open Gascom by selecting the “Gascom Adjusting Parameters via Personal Computer with 1.0” icon on the desk top. Before using the GCI Interface program for the first time it must be configured 1. Operating System Requirements properly to work with the Alpine boiler and The GCI Interface requires a PC computer running a your computer.
  • Page 60 Figure 41: Gascom Menu Tree 4. Double-click on the desired parameter. A window Using Gascom To Monitor The MCBA will open with either a field or a pull down list of From the Monitor Menu select “Monitor MCBA”. options will appear. Enter or select the desired This will bring up a window which plots the following value for the parameter.
  • Page 61 Hotwater - Indirect water heater thermostat (“1” = 2. If the signal is lower then 6 VDC, check the Calling, “0” = Not Calling) continuity of the ground wire between the ignitor and the junction box. If the ground wire is suspect Pump - Heating circulator (“1”...
  • Page 62 Table 2: nTC Sensor resistance Values...

  • Page 63: Service And Maintenance

    XII. Service and Maintenance 3. Inspect the water and gas lines to verify they are free from leaks. Call the service technician to make repairs if required. Continuously: 1. Keep the area around the boiler free from combustible materials, gasoline and other flammable vapors and liquids.
  • Page 64 10. Reinstall the burner, burner hood and fan/gas valve 3. Inspect the wiring to verify the conductors are in assembly. good condition and attached securely. 11. Reconnect any wiring which has been disconnected. 12. Inspect the heating system and correct any other deficiencies prior to restarting the boiler.
  • Page 65 f. Reconnect the switch wire pigtails to the boiler above. In general, freeze protection for new or existing systems must use specially formulated wiring and secure with wire nuts. glycol, which contains inhibitors, preventing g. Restore power supply to boiler. Fill up the trap the glycol from attacking the metallic system (see Section V “Condensate Disposal”) and components.

  • Page 67: Troubleshooting

    XIII: Troubleshooting . Troubleshooting problems where no error code is displayed. Refer to Table 25 for problems and possible causes. Table 25: No Error Code Displayed CONDITION POSSIBLE CAUSES Display Blank, Fan off, LWCO lights off • No 120VAC Power at boiler. Check breaker and wiring between breaker panel and boiler •...
  • Page 68 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 69 the condition that caused the lockout is corrected, the Trouble shooting problems where a hard lockout boiler will need to be manually reset using the RESET code is displayed. When a hard lockout occurs, the button on the display. boiler will shut down and the display will flash the letter “E”...

  • Page 70: Repair Parts

    XiV. 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 (717) 481-8400 or Fax (717) 481-8408.
  • Page 71 (Quantity) Part Number Description ALP080 ALP105 ALP150 ALP210 ALP285 ALP399 Heat Exchanger, Burner, Etc. (Key No’s 2 thru 23) 101520-01 101521-01 101522-01 101523-01 101524-01 101525-01 Heat Exchanger Assembly 101710-01 101711-01 101712-01 101713-01 101714-01 101715-01 Burner Assembly 101717-01 101718-01 101719-01 101720-01 101721-01 101722-01 M6x1 Hex Flange Nut (Not Shown)
  • Page 72 (Quantity) Part Number Description ALP080 ALP105 ALP150 ALP210 ALP285 ALP399 Gas Train Assembly 101585-01 101585-02 101585-04 101585-05 101585-06 (Key No’s 24 thru 29) Blower 101527-01 101528-01 101529-01 101530-01 Blower Inlet Shroud Assembly 101704-01 101704-02 101704-03 101704-04 Blower Outlet Gasket 101345-01 Blower Mounting Plate Gas Valve 101703-01 101703-02...
  • Page 73 (Quantity) Part Number Description ALP080 ALP105 ALP150 ALP210 ALP285 ALP399 Air Pressure Switch 80160762 101862-01 Air Pressure Switch Hose 7016039 7016046 Rubber Grommet, Condensate Trap 101595-01 Condensate Trap, Blow Molded 101239-01 Spring Clip, Condensate Trap (2) 101632-01 Blocked Condensate Drain Switch 101587-01 Condensate Comp.
  • Page 74 (Quantity) Part Number Description ALP080 ALP105 ALP150 ALP210 ALP285 ALP399 Wiring Harness (Not Shown) 101454-01 MCBA Slide Out Assembly 101230-01 (Includes all parts shown) Control Panel, MCBA 101219-01 MCBA (programmed - 0-2000’ or 0-7000’) 101866-01 101866-02 101866-03 101886-04 101886-05 101866-06 MCBA (programmed - 2001 - 7000’) 101866-08 101866-09 101866-10...
  • Page 75 (Quantity) Part Number Description ALP080 ALP105 ALP150 ALP210 ALP285 ALP399 Rubber Grommet, Gas Line 820SOL0001 101638-01 Jacket, Rear/Bottom Panel 101217-01 101217-02 101217-03 101217-04 101764-01 101764-02 Lower Front Door Assembly 101227-01 101227-02 Draw Latch 101037-01 Jacket, Left Side Panel 101215-01 101215-02 101215-03 101215-04 101765-01...
  • Page 76 (Quantity) Part Number Description ALP080 ALP105 ALP150 ALP210 ALP285 ALP399 Flue Temp Sensor 101687-01 Wire Harness (Not Shown) 101454-01 Concentric Vent Collar with Viton Cap 101598-01 101599-01 Vent Terminal Kit 101808-01 101809-01...
  • Page 77 (Quantity) Part Number Description ALP080 ALP105 ALP150 ALP210 ALP285 ALP399 MISCELLANEOUS PARTS CARTON Temperature/Pressure Gauge 8056169 External Gas Shut Off Valve 806SOL0005 101615-01 Relief Valve 81660363 81660302 Boiler Drain Valve 806603061 Boiler Stacking Brackets (4) 101679-01 Boiler Stacking Bracket Screws (12) 80860743 Outdoor Temperature Sensor (1) 101639-01...
  • Page 78 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 79 SERVICE RECORD DATE SERVICE PERFORMED...
  • Page 80 U.S. Boiler and all labor and material connected therewith, and transportation to and from Company, Inc. to ship these parts prepaid to U.S. Boiler Company, Inc. at the above U.S. Boiler Company, Inc.

This manual is also suitable for:

Burnham hydronics alpine alp105Burnham hydronics alpine alp150Burnham hydronics alpine alp210Burnham hydronics alpine alp285Burnham hydronics alpine alp399

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