Burnham ALP150 - Manuals

5 Figure 1 a : a lpine™ - Models a LP080 thru a LP210

6 Figure 1B: a lpine™ - Models a LP285 thru a LP 99

8 WaRning if you do not follow these instructions exactly, a fire or explosion may result causing property damage or personal injury. DangER Do not install boiler where gasoline or other flammable vapors or liquids, or sources of hydrocarbons (i.e. bleaches, cleaners, chemicals, sprays, paint remove...

9 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 onl...

10 iV. Venting 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 specified.The use of thermal i...

11 2. The Alpine™ is designed to be installed as a Direct Vent boiler. The air for combustion is supplied directly to the burner enclosure from outdoors and flue gases are vented directly outdoors (through wall or roof). 3. The following combustion air/vent system options are approved for use with t...

12 Vent Pipe Pipe Direction Enclosure Minimum Clearance To Combustible Material, Inches CPVC/PVC Venting Vertical or Horizontal Enclosed at all Sides 1” Vent/0” Combustion Air Table 5: Clearances from Vent Piping to Combustible Material Vent System Components Part Number Quantity ALP080 & ALP105...

1 Boiler Model 3” Combustion Air Pipe (Equivalent Length) 4” Combustion Air Pipe (Equivalent Length) 3” Vent Pipe (Equivalent Length) 4” Vent Pipe (Equivalent Length) Min. Max. Min. Max. Min. Max. Min. Max. ALP080 21-7/8 In. 60 Ft. --- --- 21-7/8 In. 60 Ft. --- --- ALP105 21-7/8 In. 60 Ft. --- --- 2...

1 6. Remove the Silicone flue sensor cap from the vent carton and press onto the two pipe vent system connector for CPVC/PVC sensor port. Remove the tape holding the flue sensor and insert the flue temperature sensor into the flue sensor plug until it is firmly engaged. See Figure 4. 7. Near-Boiler ...

15 6. Install Rodent Screen and Vent Terminal (supplied with boiler), see Figure 8 for appropriate configuration. 7. Apply sealant between vent pipe and opening/ thimble to provide weather-tight seal. Sealant should not restrain the expansion of the vent pipe. Combustion Air Piping - Horizontal 1. S...

16 7. Install Rodent Screen and Combustion Air Terminal (supplied with boiler), see Figure 8 for appropriate configuration. 8. Apply sealant between vent pipe and opening to provide weather-tight seal F. CPVC/PVC Vertical Venting System Refer to Figures 3, 4, 5, 8, 9 & 10. nOTiCE Roof penetratio...

1 a. Size roof opening to maintain minimum clearance of 1 inch from combustible materials. b. Extend vent pipe to maintain minimum vertical and horizontal distance of twelve (12) inches from roof surface. Allow additional vertical distance for expected snow accumulation. Provide brace as required. C...

18 7. Brace exterior piping if required. Combustion Air Piping - Vertical 1. See Paragraph D for instructions on attaching the vent system connector to the boiler. 2. Do not exceed maximum combustion air length. Refer to Table 7 for pipe diameters and allowable lengths. 3. Horizontal combustion air ...

19 5. Install maximum vertical run of seven (7) feet of Schedule 40 PVC vent pipe. See Figure 11. 6. At top of vent pipe length install another PVC 90° elbow so that elbow leg is opposite the building’s exterior surface. 7. Install Rodent Screen and Combustion Air Terminal (supplied with boiler), se...

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. 3. Use noncombustible ¾ inch pipe s...

21 The direct vent termination location is restricted as follows: a. Minimum twelve (12) inches above grade plus normally expected snow accumulation level, or minimum seven (7) feet above grade, if direct vent terminal is located adjacent to public walkway. Do not install the terminal over public wa...

2 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 sides to seal it to interior wall. j. Lubricate the brown gaske...

25 Figure 22: Cutting Straight Pipe Figure 2: Joining Cuttable Pipe 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 abov...

26 Figure 26: Cutting Vertical Terminal a. Determine the centerline of the terminal location on the roof. For flat roof, cut either 5-1/2” diameter hole (80/125 mm concentric vent size) or 6-1/2” diameter hole (100/150 mm concentric vent size) for the terminal. For sloped roof, cut a hole in the roo...

2 Table 10: Cut-To-Length Extensions (Cuttable) Part No. Component Description Size 101163-01 Cut-To-Length Extension, 500 mm (19-1/2”) 80/125 mm 101162-01 Cut-To-Length Extension, 1000 mm (39”) 101550-01 Cut-To-Length Extension, 500 mm (19-1/2”) 100/150 mm 101551-01 Cut-To-Length Extension, 1000 mm...

29 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 ...

1 nOTiCE Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components, and can lead to boiler failure. Burnham’s Standard Warranty does not cover problems caused by oxygen contamination of boiler water or scale (lime) build-up caused by frequent addition of water.Do ...

B. Piping System To Be Employed. Alpine (ALP) boilers are designed to operate in a closed loop pressurized system. Minimum pressure in the boiler must be 12 PSI. Proper operation of the Alpine (ALP) boiler requires that the water flow through the boiler remain within the limits shown in Table 11, an...

nOTiCE Where it is not possible to install a separate boiler loop, the system circulator must be sized to ensure that the flow through boiler stays within the defined parameters to prevent overheating when the boiler is fired at it’s full rated input. Install a flow meter to measure the flow, or fir...

5 D. Special Situation Piping Installation Requirements Observe the following guidelines when making the actual installation of the boiler piping for special situations: 1. Systems containing high level of dissolved oxygen – Many hydronic systems contain enough dissolved oxygen to cause severe corro...

6 Vii. gas Piping WaRning Failure to properly pipe gas supply to boiler may result in improper operation and damage to the boiler or structure. always assure gas piping is absolutely leak free and of the proper size and type for the connected load. an additional gas pressure regulator may be needed....

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 Size, In. Inside Diameter, In. Length of Pipe, Ft. 10 20 30 40 50 60 70 80 90 100 ½ 0.622 88 60 48 41 37 33 31 29 27 25 ¾ ...

8 C. 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. 1. Protect boiler gas control valve. For all testing over ½ psig, boiler and its individual shutoff valve must be disconnected from gas su...

9 Viii. Electrical A. General. Install wiring and electrically ground boiler in accordance with authority having jurisdiction or, in the absence of such requirements, follow the National Electrical Code , NFPA 70, and/or CSA C22.1 Electrical Code. B. A separate electrical circuit must be run from th...

56 iX. Boiler Stacking For installations with unusually high space heating and/or domestic hot water heating loads, where employing two (2) Alpine (ALP) boilers will offer the benefits of greater operational efficiency, floor space savings and boiler redundancy, the Alpine (ALP) boilers may be insta...

58 X. Modular installation A. General Guidelines 1. Read and follow all venting, combustion air, water piping, gas piping and electrical instructions contained in the Installation, Operating and Service Instructions unless otherwise instructed in this section. 2. Consult Local Building Codes or Nati...

61 If vertical vent terminals cannot end in one plane, they must be spaced no closer than three (3) feet horizontally. 6. Chimney chase concentric venting is permitted for modules, when stackable, providing concentric vertical (roof) vent terminals, if level with each other, are spaced no closer the...

66 A. Verify that the venting, water piping, gas piping and electrical system are installed properly. Refer to installation instructions contained in this manual. B. Confirm all electrical, water and gas supplies are turned off at the source and that vent is clear of obstructions. C. Confirm that al...

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

68 H. Purge Air From Gas Train Upon initial start-up, the gas train will be filled with air. Even if the gas line has been completely purged of air, it may take several tries for ignition before a flame is established. If more than 5 tries for ignition are needed, it will be necessary to press the r...

69 Boiler Model Gas Valve Size (NPT) (Dungs) Gas Valve Model Fuel Converted Planned Installation Altitude Range From To ALP080 1/2” GB-WND 055 D01 S00 253082 Natural Gas LP 0 - 7,000 Ft. ALP105 GB-WND 055 D01 S00 253083 ALP150 ALP210 GB-WND 055 D01 S00 253084 ALP285 3/4” GB-WND 057 D01 S00 253085 AL...

0 6. After the burner lights, force the burner to high fire by simultaneously pressing and holding the “Mode” button and “+“ button. After a few seconds, the display should flash “H”, indicating that the boiler has been driven to high fire. Allow the boiler to operate for approximately 5 minutes bef...

1 Fuel Inlet Pressure (Inches w.c.) Min. Max. Natural Gas 4.0 14.0 LP 11.0 14.0 Table 2: inlet Pressure Limits • Apply the “Boiler Conversion Label” to a conspicuous surface on, or adjacent to, the outer boiler jacket. Fill in the date of the conversion and the name and address of the company making...

2 Xii. Operation A. The Alpine (ALP) boiler uses a microprocessor based Honeywell control, known as a “MCBA”, to manage all boiler functions including flame supervision and modulation. Two set point or “target” boiler supply temperatures are stored in the MCBA’s memory; one for space heating and one...

Table 25: Parameter Descriptions Access Code Parameter No. Description Factory Setting ALP080 ALP105 ALP150 ALP210 ALP285 ALP399 no access Code needed 1 T3set DHW 140 2 DHW system 1 (On) 3 CH system 1 (On) 4 T1top CH Mode 190 Access Code Required 5 T1foot CH Mode 130 6 T4 minimum 0 7 T4 maximum 60 8...

5 D. Two basic types of errors codes are shown on the display: 1. Soft Lockout Codes – 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. A list of these codes, and their meanings, is sh...

6 Figure 51: Outdoor Reset Curve II. Field Adjustable Boiler Operating Parameters MCBA control factory programmed operating parameters will result in satisfactory operation under most conditions. However, because all systems are different, there may exist situations where boiler operation may be enh...

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

80 B. Adjusting Parameters via Personal Computer with GCI Interface 1. Operating System Requirements The GCI Interface requires a PC computer running a Windows 98/NT/2000 or XP operating system. In addition, the PC must have an open serial port. 2. Connecting Personal Computer to MCBA Control a. Con...

82 III. Component Test Procedures A. Flame Signal Check 1. The flame signal can be checked between terminal number 7 on the low voltage terminal strip and ground. A good signal reading should be 6 VDC or greater. Hotwater - Indirect water heater thermostat (“1” = Calling, “0” = Not Calling) Pump - H...

8 Xiii. Service and Maintenance nOTiCE Warranty does not cover boiler damage or malfunction if the following steps are not performed at the intervals specified. A. Continuously: 1. Keep the area around the boiler free from combustible materials, gasoline and other flammable vapors and liquids. 2. Ke...

85 3. Inspect the wiring to verify the conductors are in good condition and attached securely. CaUTiOn Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing. 4. Remove the ignition electrode a...

86 b. Equivalent system freeze protection products may be used in lieu of product referenced above. In general, freeze protection for new or existing systems must use specially formulated glycol, which contains inhibitors, preventing the glycol from attacking the metallic system components. Insure t...

8 Figure 57: Condensate Overflow Switch Orientation

88 XiV: Troubleshooting Figure 58: MBCa Fuse Location CONDITION POSSIBLE CAUSES Display Blank, Fan off, LWCO lights off • No 120VAC Power at boiler. Check breaker and wiring between breaker panel and boiler Display Panel Blank, Fan running • Loose 120VAC connection wiring between boiler J-Box and MC...

89 B. 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 c...

90 Table 0: Hard Lockout Codes Displayed CODE CONDITION POSSIBLE CAUSES E 00 A flame signal was present when there should be no flame. • Defective gas valve - make sure inlet pressure is below maximum on rating plate before replacing valve. E 02 Flame failure after 5 tries to restart • No gas pressu...

98 Key No. Description (Quantity) Part Number ALP080 ALP105 ALP150 ALP210 ALP285 ALP399 MiSCELLanEOUS PaRTS CaRTOn 101777-01 101777-02 101777-03 73 Temperature/Pressure Gauge 8056169 74 External Gas Shut Off Valve 806SOL0005 101615-01 75 Relief Valve 81660363 81660302 77 Boiler Drain Valve 806603061...

99 important Product Safety information Refractory Ceramic Fiber Product Warning : The Repair Parts list designates parts that contain refracto ry ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to temperatures about 1805°F, such as during direct flame cont...

100 e. Boilers installed outside the 48 contiguous United States, the State of Alaska, and Canada. f. Damage to the boiler and /or property due to installation or operation of the boiler that is not in accordance with the boiler installation and operating instruction manual. g. Any damage of failure...