Burnham ALP150 Specifications

101602-01R2-9/08Price - $5.00DNAGNITAREPO,NOITALLATSNIROFSNOITCURTSNIECIVRES™ENIPLAYCNEICIFFEHGIHGNISNEDNOCTNEVTCERIDRELIOBRETAWTOHDERIF-SAG As an EN

10IV. VentingWARNINGFailure to vent this boiler in accordance with these instructions could cause products of combustion to enter the building result

100e. Boilers installed outside the 48 contiguous United States, the State of Alaska, and Canada.f. Damage to the boiler and /or property due to in

112. The Alpine™ is designed to be installed as a Direct Vent boiler. The air for combustion is supplied directly to the burner enclosure from outdo

12Vent Pipe Pipe Direction EnclosureMinimum Clearance ToCombustible Material, InchesCPVC/PVC Venting Vertical or Horizontal Enclosed at all Sides 1” V

13Boiler Model3” Combustion Air Pipe(Equivalent Length)4” Combustion Air Pipe (Equivalent Length)3” Vent Pipe (Equivalent Length)4” Vent Pipe (Equival

146. Remove the Silicone ue sensor cap from the vent carton and press onto the two pipe vent system connector for CPVC/PVC sensor port. Remove the

156. Install Rodent Screen and Vent Terminal (supplied with boiler), see Figure 8 for appropriate conguration.7. Apply sealant between vent pipe an

167. Install Rodent Screen and Combustion Air Terminal (supplied with boiler), see Figure 8 for appropriate conguration.8. Apply sealant between ve

17a. Size roof opening to maintain minimum clearance of 1 inch from combustible materials.b. Extend vent pipe to maintain minimum vertical and horiz

187. Brace exterior piping if required.Combustion Air Piping - Vertical1. See Paragraph D for instructions on attaching the vent system connector to

195. 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

2IMPORTANT INFORMATION - READ CAREFULLYNOTE: The equipment shall be installed in accordance with those installation regulations enforced in the area

20Figure 12: Field Installation of Boiler Concentric Vent Collarcodes. Contact local building or re ofcials about restrictions and installation in

21The direct vent termination location is restricted as follows:a. Minimum twelve (12) inches above grade plus normally expected snow accumulation le

22b. Measure dimension “L” from exterior wall outer surface to the end of the last tting (or end of installed Boiler Concentric Vent Collar). See F

23i. Install the supplied Inside Wall Plate onto the shortened Horizontal (Wall) Terminal interior end and move the plate to cover interior wall cut

24Figure 19: Vertical Concentric Vent Installationouter pipes to start the screw. Use a drill stop or other means to ensure that the drill bit does n

25Figure 22: Cutting Straight PipeFigure 23: Joining Cuttable PipeFigure 24: Joining Non-Cuttable Pipeb. Push the male end of the rst tting into

26Figure 26: Cutting Vertical Terminala. Determine the centerline of the terminal location on the roof. For at roof, cut either 5-1/2” diameter ho

27Table 10: Cut-To-Length Extensions (Cuttable)Part No. Component Description Size101163-01Cut-To-Length Extension, 500 mm (19-1/2”)80/125 mm101162-01

28Figure 28: Chimney Chase Installation

29V. Condensate DisposalA. Condensate Trap and Drain Line.1. All condensate, which forms in the boiler or vent system, collects in the sump under he

3WARNINGThis boiler requires regular maintenance and service to operate safely. Follow the instructions contained in this manual.Improper installatio

30Figure 29: Condensate Trap and Drain Line

31NOTICEOxygen contamination of boiler water will cause corrosion of iron and steel boiler components, and can lead to boiler failure. Burnham’

321. ALP080 thru ALP285 Boiler Models a. Locate and remove ¾” NPT x close black nipple, ¾” NPT black tee, ¾” MPT x ¾” FPT Pressure Relief Valve, ¾”

33B. Piping System To Be Employed. Alpine (ALP) boilers are designed to operate in a closed loop pressurized system. Minimum pressure in the boiler

34Table 12A: Recommended Circulator Models for Alpine (ALP) Boilers Based on 25°F Temperature Differential and Up to 75 ft. Eq

35Boiler ModelBoiler Supply Connection, Inch, FPTBoiler Return Connection, Inch, FPTNear-Boiler Piping Supply Pipe Size, InchNear-Boiler Piping Return

36Table 12B (continued): Space Heating with Indirect Water Heating - Recommended Circulator Models for Alpine (ALP) Boilers and Al

37Table 13: Fitting and Valve Equivalent LengthCopper Fitting and Sweat Valve Equivalent Length (Ft)Fitting or ValveDescriptionCopper Pipe or Valve S

38Figure 31A: Near Boiler Piping - Heating Only (with Central Heating Circulators)

39Figure 31B: Near Boiler Piping - Heating Only (with Central Heating Zone Valves)

4Table of Contents I. Product Description, Specifications and Dimensional Data...4 II. Pre-Installation ...

40Figure 32A: Near Boiler Piping - Heating Plus Indirect Water Heater (with Central Heating Circulators)

41Figure 32B: Near Boiler Piping - Heating Plus Indirect Water Heater (with Central Heating Zone Valves)

42Figure 32C: Near Boiler Piping - Heating (with Central Heating Circulators) Plus Alternately Piped Indirect Water Heater

43Figure 32D: Near Boiler Piping - Heating (with Central Heating Zone Valves) Plus Alternately Piped Indirect Water Heater

44NOTICEWhere it is not possible to install a separate boiler loop, the system circulator must be sized to ensure that the ow through boiler stays wi

45D. Special Situation Piping Installation Requirements Observe the following guidelines when making the actual installation of the boiler piping fo

46VII. Gas PipingWARNINGFailure to properly pipe gas supply to boiler may result in improper operation and damage to the boiler or structure. Alway

47Table 14B: 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

48C. Pressure test. See Table 17 for Alpine Min./Max. Pressure Ratings. The boiler and its gas connection must be leak tested before placing boiler

49VIII. ElectricalA. General. Install wiring and electrically ground boiler in accordance with authority having jurisdiction or, in the absence of s

5Figure 1A: Alpine™ - Models ALP080 thru ALP210

50• Black – Line voltage “hot”• White – “Neutral” for boiler and circulators• Red – “Heating” circulator “hot”• Blue – “Indirect Water Heater “ ci

51Figure 35: Wiring Connections Diagram

52Figure 36: Ladder Diagram

53Figure 37A: Modied Wiring For DHW Priority When Using Low Flow Circulator Piped Off System Header -Heating (with Central Heating Circulators) Plus

54Figure 37B: Modied Wiring For DHW Priority When Using Low Flow Circulator Piped Off System Header -Heating (with Central Heating Zone Valves) Plus

55Figure 38: Wiring for MCBA Modulating Boiler Control Time Delay Relay Box5. If the boiler installation site may be subject to low supply voltage c

56IX. Boiler Stacking For installations with unusually high space heating and/or domestic hot water heating loads, where employing two (2) Alpine (A

57vertical (roof) vent terminals, if level with each other, are spaced no closer then 12 inches horizontally. If vertical vent terminals cannot end i

58X. Modular InstallationA. General Guidelines1. Read and follow all venting, combustion air, water piping, gas piping and electrical instructions

59Figure 40: Modular Boiler Direct Vent Termination

6Figure 1B: Alpine™ - Models ALP285 thru ALP399

60Figure 41: Modular Boiler Concentric Vent Termination

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 ve

62Figure 42: Modular Boiler Water Piping w/Domestic Hot Water HeaterNOTICEInstalling a low water cutoff in the system piping of modular boilers is st

63Figure 43: Modular Boiler Water Piping w/Domestic Hot Water Heater (Continued)

64Figure 44: Modular Wiring Diagram w/Tekmar 265 ControlTekmar 265 Based Control System (or equal)Sequence of OperationThe Tekmar 265 Control (or equ

65Tekmar 264 Based Control System (or equal)Sequence of OperationThe Tekmar 264 Control (or equal) can control up to four (4) boilers and an Indirect

66A. Verify that the venting, water piping, gas piping and electrical system are installed properly. Refer to installation instructions contained in

67Alpine™ Series Lighting and Operating InstructionsFigure 46: Lighting Instructions

68H. Purge Air From Gas Train Upon initial start-up, the gas train will be lled with air. Even if the gas line has been completely purged of air,

69Boiler ModelGas Valve Size (NPT)(Dungs)Gas Valve ModelFuel ConvertedPlanned Installation Altitude RangeFrom ToALP0801/2”GB-WND 055 D01 S00 253082Nat

7Table 2A: Rating Data - Models ALP080 thru ALP399 (0 to 2000 Feet Elevation Above Sea Level)Table 2B: Rating Data - Models ALP080 thru ALP399 (2001

706. After the burner lights, force the burner to high re by simultaneously pressing and holding the “Mode” button and “+“ button. After a few seco

71FuelInlet Pressure (Inches w.c.)Min. Max.Natural Gas 4.0 14.0LP 11.0 14.0Table 24: Inlet Pressure Limits• Apply the “Boiler Conversion Label” to

72XII. OperationA. The Alpine (ALP) boiler uses a microprocessor based Honeywell control, known as a “MCBA”, to manage all boiler functions including

73Table 25: Parameter DescriptionsAccess CodeParameter No.DescriptionFactory SettingALP080 ALP105 ALP150 ALP210 ALP285 ALP399No Access Code Needed1 T

74Figure 50: Basic Menu Tree

75D. 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

76Figure 51: Outdoor Reset CurveII. Field Adjustable Boiler Operating Parameters MCBA control factory programmed operating parameters

77Figure 52: Expanded Menu Tree (Cont’d on next page)

78Figure 52: Expanded Menu Tree (cont’d.)Figure 53: Adjusting Boiler Water Reset Curve

7914; Parameter 13 denes the “thousands” and hundreds” places and Parameter 14 denes the “tens” and “ones” places. The ignition fan speed is only a

8WARNINGIf you do not follow these instructions exactly, a re or explosion may result causing property damage or personal injury.DANGERDo not

80B. Adjusting Parameters via Personal Computer with GCI Interface1. Operating System Requirements The GCI Interface requires a PC computer running

81Figure 55: Gascom Menu Tree4. Double-click on the desired parameter. A window will open with either a eld or a pull down list of options will ap

82III. Component Test Procedures A. Flame Signal Check1. The ame signal can be checked between terminal number 7 on the low voltage terminal

83Table 27: NTC Sensor Resistance Values

84XIII. Service and MaintenanceNOTICEWarranty does not cover boiler damage or malfunction if the following steps are not performed at the intervals sp

853. Inspect the wiring to verify the conductors are in good condition and attached securely.CAUTIONLabel all wires prior to disconnection when servi

86b. Equivalent system freeze protection products may be used in lieu of product referenced above. In general, freeze protection for new or existing

87Figure 57: Condensate Overow Switch Orientation

88XIV: TroubleshootingFigure 58: MBCA Fuse LocationCONDITION POSSIBLE CAUSESDisplay Blank, Fan off, LWCO lights off • No 120VAC Power at boiler. Che

89B. Trouble shooting problems where a soft lockout code is displayed. When a soft lockout occurs, the boiler will shut down and the display will alt

9III. Unpacking BoilerCAUTIONDo not drop boiler. A. Move boiler to approximate installed position.B. Remove all crate fasteners.C. Lift and remo

90Table 30: Hard Lockout Codes DisplayedCODE CONDITION POSSIBLE CAUSES E 00A ame signal was present when there should be no ame.• Defective gas val

91XV. Repair Parts All Alpine™ Series Repair Parts may be obtained through your local Burnham Wholesale distributor. Should you require assistance

92Key No.Description(Quantity) Part NumberALP080 ALP105 ALP150 ALP210 ALP285 ALP3991 Heat Exchanger, Burner, Etc. (Key No’s 2 thru 23) 101520-01 10152

93Key No.Description(Quantity) Part NumberALP080 ALP105 ALP150 ALP210 ALP285 ALP39923Gas Train Assembly(Key No’s 24 thru 29)101585-01 101585-02 101585

94Key No.Description(Quantity) Part NumberALP080 ALP105 ALP150 ALP210 ALP285 ALP39935 Air Pressure Switch 80160762 101862-0136 Air Pressure Switch Hos

95Key No.Description(Quantity) Part NumberALP080 ALP105 ALP150 ALP210 ALP285 ALP39942 Wiring Harness (Not Shown) 101454-0143MCBA Slide Out Assembly(In

96Key No.Description(Quantity) Part NumberALP080 ALP105 ALP150 ALP210 ALP285 ALP39930 Rubber Grommet, Gas Line 820SOL0001101638-0151 Jacket, Rear/Bott

97Key No.Description(Quantity) Part NumberALP080 ALP105 ALP150 ALP210 ALP285 ALP39934 Flue Temp Sensor 101687-0142 Wire Harness (Not Shown) 101454-017

98Key No. Description(Quantity) Part NumberALP080 ALP105 ALP150 ALP210 ALP285 ALP399MISCELLANEOUS PARTS CARTON101777-01 101777-02 101777-0373 Temperat

99Important Product Safety InformationRefractory Ceramic Fiber ProductWarning:The Repair Parts list designates parts that contain refractory ceramic f