Instruction/ maintenance manual of the product ALP399 Burnham
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101602-01R2-9/08 Price - $5.00 D N A G N I T A R E P O , N O I T A L L A T S N I R O F S N O I T C U R T S N I E C I V R E S ™ E N I P L A Y C N E I C I F F E H G I H G N I S N E D N O C T N E V T C.
2 IMPOR T ANT INFORMA TION - READ CAREFULL Y 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.
3 W aRning This boiler requires regular maintenance and service to operate safely . Follow the instructions contained in this manual. improper insta llation, adjus tment, alterat ion, service or maintenance can cause property damage, personal injury or loss of life.
4 T able of Contents I. P roduct Description, Specifications and Dimensional Data.................... 4 II. P re-Installation ............................... 8 III. U npacking Boiler ........................... 9 IV . V enting .......................
5 Figure 1a: alpine™ - Models aLP080 thru aLP210.
6 Figure 1B: alpine™ - Models aLP285 thru aLP399.
7 T able 2a: Rating Data - Models aLP080 thru aLP399 (0 to 2000 Feet Elevation above Sea Level) T able 2B: Rating Data - Models aLP080 thru aLP399 (2001 to 7000 Feet Elevation above Sea Level) alpine .
8 W aRning if you do not follow these instructions exactly , a re or explosion may result causing property damage or personal injury . DangER Do not install boiler where gasoline or other ammable vapors or liquids, or sources of hydrocarbons (i.
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 .
10 iV . V enting W aRning 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 specied.
1 1 2. The Alpine™ is designed to be installed as a Direct V ent boiler . The air for combustion is supplied directly to the burner enclosure from outdoors and ue gases are vented directly outdoors (through wall or roof). 3. The following combustion air/vent system options are approved for use with the Alpine™ boilers: i.
12 V ent Pipe Pipe Direction Enclosure Minimum Clearance T o Combustible Material, Inches CPVC/PVC V enting V ertical or Horizontal Enclosed at all Sides 1” V ent/0” Combustion Air T able 5: Clear.
13 Boiler Model 3” Combustion Air Pipe (Equivalent Length) 4” Combustion Air Pipe (Equivalent Length) 3” V ent Pipe (Equivalent Length) 4” V ent Pipe (Equivalent Length) Min. Max. Min. Max. Min. Max. Min. Max. ALP080 21-7/8 In. 60 Ft. --- --- 21-7/8 In.
14 6. 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 tape holding the ue sensor and insert the ue temperature sensor into the ue sensor plug until it is rmly engaged.
15 6. Install Rodent Screen and V ent T erminal (supplied with boiler), see Figure 8 for appropriate conguration. 7. Apply sealant between vent pipe and opening/ thimble to provide weather-tight seal. Sealant should not restrain the expansion of the vent pipe.
16 7. Install Rodent Screen and Combustion Air T erminal (supplied with boiler), see Figure 8 for appropriate conguration. 8. Apply sealant between vent pipe and opening to provide weather-tight seal F . CPVC/PVC V ertical V enting System Refer to Figures 3, 4, 5, 8, 9 & 10.
17 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.
18 7. Brace exterior piping if required. Combustion Air Piping - V ertical 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 T able 7 for pipe diameters and allowable lengths.
19 5. Install maximum vertical run of seven (7) feet of Schedule 40 PVC vent pipe. See Figure 1 1. 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 T erminal (supplied with boiler), see Figure 8 for appropriate conguration.
20 Figure 12: Field installation of Boiler Concentric V ent Collar codes. Contact local building or re ofcials about restrictions and installation inspection in your area. 2. Horizontal vent pipe must maintain a minimum ¼ inch per foot slope towards the boiler .
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 .
22 b. Measure dimension “L” from exterior wall outer surface to the end of the last tting (or end of installed Boiler Concentric V ent Collar). See Figure 14 ‘Dimension “L”’. several marks around the outer pipe to establish a cut line. See Figure 15 ‘ Cutting Outer Pipe’.
23 i. Install the supplied Inside W all Plate onto the shortened Horizontal (W all) T erminal 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.
24 Figure 19: V ertical Concentric V ent installation outer pipes to start the screw . Use a drill stop or other means to ensur e that the drill bit does not penetrate more than 3/8” into the outer pipe. Do not use sheet metal screws longer than ½”.
25 Figure 22: Cutting Straight Pipe Figure 23: Joining Cuttable Pipe Figure 24: Joining non-Cuttable Pipe b. Push the male end of the rst tting 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.
26 Figure 26: Cutting V ertical T erminal a. Determine the centerline of the terminal location on the roof. For at 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.
27 T able 10: Cut-T o-Length Extensions (Cuttable) Part No. Component Description Size 101 163-01 Cut-T o-Length Extension, 500 mm (19-1/2”) 80/125 mm 101 162-01 Cut-T o-Length Extension, 1000 mm (3.
28 Figure 28: Chimney Chase installation.
29 V . Condensate Disposal A. Condensate T rap 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 ue gases in the boiler .
30 Figure 29: Condensate T rap and Drain Line.
31 nOTiCE Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components, and can lead to boiler failure. Burnham’s Standard W arranty does not cover problems caused by oxygen contamination of boiler water or scale (lime) build-up caused by frequent addition of water .
32 1. 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 V alve, ¾” NPT Drain V alve.
33 B. Piping System T o 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 ow through the boiler remain within the limits shown in T able 1 1, any time the boiler is ring.
34 T able 12a: Recommended Circulator Models for alpine (aLP) Boilers Based on 25°F T emperature Differential and Up to 75 ft. Equivalent Length Near-Boiler Piping - Space Heating Circulator Boiler M.
35 Boiler Model Boiler Supply Connecti on, Inch, FPT Boiler Return Connecti on, Inch, FPT Near- Boiler Piping Supply Pipe Size, Inch Near- Boiler Piping Return Pipe Size, Inch Max Allowable Flow thru .
36 T able 12B (continued): Space Heating with Indirect Water Heating - Recommended Circulator Models for Alpine (ALP) Boilers and Alliance SL Indirect W ater Heaters Installed as Part of Near-Boiler Piping Up to 75 Ft.
37 T able 13: Fitting and V alve Equivalent Length Copper Fitting and Sweat V alve Equivalent Length (Ft) Fitting or V alve Description Copper Pipe or V alve Size 1 1¼ 1½ 90° Elbow 2.5 3.0 4.0 45° Elbow 1.0 1.2 1.5 T ee (thru ow) 0.5 0.6 0.8 T ee (Branch ow) 4.
38 Figure 31a: near Boiler Piping - Heating Only (with Central Heating Circulators).
39 Figure 31B: near Boiler Piping - Heating Only (with Central Heating zone V alves).
40 Figure 32a: near Boiler Piping - Heating Plus indirect W ater Heater (with Central Heating Circulators).
41 Figure 32B: near Boiler Piping - Heating Plus indirect W ater Heater (with Central Heating zone V alves).
42 Figure 32C: near Boiler Piping - Heating (with Central Heating Circulators) Plus alternately Piped indirect Water Heater.
43 Figure 32D: near Boiler Piping - Heating (with Central Heating zone V alves) Plus alternately Piped indirect W ater Heater.
44 nOTiCE Where it is not possible to install a separate boiler loop, the system circulator must be sized to ensure that the ow through boiler stays within the dened parameters to prevent overheating when the boiler is red at it’ s full rated input.
45 D. Special Situation Piping Installation Requirements Observe the following guidelines when making the actual installation of the boiler piping for special situations: 1.
46 Vii. gas Piping W aRning 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.
47 T able 14B: Maximum Capacity of Schedule 40 Black Pipe in CFH* (LP gas) For gas Pressures of 0.5 psig or Less inlet Pressure 1 1.0 inch W .C.; 0.3 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.
48 C. Pressur e test. See T able 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 supply piping.
49 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 , NFP A 70, and/or CSA C22.1 Electrical Code. B.
50 • Black – Line voltage “hot” • White – “Neutral” for boiler and circulators • Red – “Heating” circulator “hot” • Blue – “Indirect W ater Heater “ circulator “hot” • Green – Ground connection 2. Maximum circulator continuous current draw is 2A.
51 Figure 35: Wiring Connections Diagram.
52 Figure 36: Ladder Diagram.
53 Figure 37A: Modied Wiring For DHW Priority When Using Low Flow Circulator Piped Off System Header - Heating (with Central Heating Circulators) Plus alternately Piped indirect Water Heater.
54 Figure 37B: Modied Wiring For DHW Priority When Using Low Flow Circulator Piped Off System Header - Heating (with Central Heating zone V alves) Plus alternately Piped indirect W ater Heater.
55 Figure 38: 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 T ime Delay Relay Box (P/N 101693-01) installation is strongly recommended.
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 benets of greater operational efciency , oor space savings and boiler redundancy , the Alpine (ALP) boilers may be installed stacked one on the top of the other .
57 vertical (roof) vent terminals, if level with each other , are spaced no closer then 12 inches horizontally . If vertical vent terminals cannot end in one plane, they must be spaced no closer then three (3) feet horizontally . Follow instructions in Section IV “V enting” of the manual for specics of individual boiler vent termination.
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.
59 Figure 40: Modular Boiler Direct V ent T ermination.
60 Figure 41: Modular Boiler Concentric V ent T ermination.
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 then 12 inches horizontally .
62 Figure 42: Modular Boiler W ater Piping w/Domestic Hot Water Heater nOTiCE installing a low water cutoff in the system piping of modular boilers is strongly recommended and may be required by Local Codes.
63 Figure 43: Modular Boiler W ater Piping w/Domestic Hot Water Heater (Continued).
64 Figure 44: Modular Wiring Diagram w/T ekmar 265 Control T ekmar 265 Based Control System (or equal) Sequence of Operation The T ekmar 265 Control (or equal) can control either 3 modulating boilers or 2 modulating boilers and an Indirect W ater Heater .
65 T ekmar 264 Based Control System (or equal) Sequence of Operation The T ekmar 264 Control (or equal) can control up to four (4) boilers and an Indirect W ater Heater by utilizing stage ring.
66 A. V erify that the venting, water piping, gas piping and electrical system are installed properly . Refer to installation instructions contained in this manual. B. Conrm all electrical, water and gas supplies are turned off at the source and that vent is clear of obstructions.
67 Alpine™ Series Lighting and Operating Instructions Figure 46: Lighting instructions.
68 H. Purge Air Fr om Gas T rain Upon initial start-up, the gas train will be lled with air . Even if the gas line has been completely purged of air , it may take several tries for ignition before a ame is established. If more than 5 tries for ignition are needed, it will be necessary to press the reset button to restart the boiler .
69 Boiler Model Gas V alve Size (NPT) (Dungs) Gas V alve Model Fuel Converted Planned Installation Altitude Range From T o 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 ALP399 GB-WND 057 D01 S00 253086 3.
70 6. After the burner lights, force the burner to high re by simultaneously pressing and holding the “Mode” button and “+“ button. After a few seconds, the display should ash “H”, indicating that the boiler has been driven to high re.
71 Fuel Inlet Pressure (Inches w .c.) Min. Max. Natural Gas 4.0 14.0 LP 1 1.0 14.0 T able 24: inlet Pressure Limits • Apply the “Boiler Conversion Label” to a conspicuous surface on, or adjacent to, the outer boiler jacket.
72 Xii. Operation A. The Alpine (ALP) boiler uses a microprocessor based Honeywell control, known as a “MCBA”, to manage all boiler functions including ame supervision and modulation. T wo set point or “target” boiler supply temperatures are stored in the MCBA ’ s memory; one for space heating and one for domestic water production.
73 T able 25: Parameter Descriptions Access Code Paramet er 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 sys.
74 Figure 50: Basic Menu T ree.
75 D. T wo 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.
76 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.
77 Figure 52: Expanded Menu T ree (Cont’d on next page).
78 Figure 52: Expanded Menu T ree (cont’d.) Figure 53: adjusting Boiler Water Reset Curve.
79 14; Parameter 13 denes the “thousands” and hundreds” places and Parameter 14 denes the “tens” and “ones” places. The ignition fan speed is only adjustable in increments of hundreds, so only one parameter (19) is required to dene it.
80 B. Adjusting Parameters via Personal Computer with GCI Interface 1. Operating System Requirements The GCI Interface requires a PC computer running a W indows 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.
81 Figure 55: gascom Menu T ree 4. Double-click on the desired parameter . A window will open with either a eld or a pull down list of options will appear . Enter or select the desired value for the parameter . 5. Click OK. 6. Repeat Steps (3) - (5) to change any other desired parameters.
82 III. Component T est Procedur es A. Flame Signal Check 1. The ame signal can be checked between terminal number 7 on the low voltage terminal strip and ground.
83 T able 27: nTC Sensor Resistance V alues.
84 Xiii. Service and Maintenance nOTiCE W arranty does not cover boiler damage or malfunction if the following steps are not performed at the intervals specied. A. Continuously: 1. Keep the area around the boiler free from combustible materials, gasoline and other ammable vapors and liquids.
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. V erify proper operation after servicing.
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.
87 Figure 57: Condensate Overow Switch Orientation.
88 XiV : T roubleshooting Figure 58: MBCa Fuse Location CONDITION POSSIBLE CAUSES Display Blank, Fan off, L WCO lights off • No 120V AC Power at boiler .
89 B. T rouble shooting problems wher e 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.
90 T able 30: Hard Lockout Codes Displayed CODE CONDITION POSSIBLE CAUSES E 00 A ame signal was present when there should be no ame. • Defective gas valve - make sure inlet pressure is below maximum on rating plate before replacing valve.
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, .
92 Key No. Description (Quantity) Part Number ALP080 ALP105 ALP150 ALP210 ALP285 ALP399 1 Heat Exchanger , Burner , Etc. (Key No’s 2 thru 23) 101520-01 101521-01 101522-01 101523-01 101524-01 101525.
93 Key No. Description (Quantity) Part Number ALP080 ALP105 ALP150 ALP210 ALP285 ALP399 23 Gas T rain Assembly (Key No’s 24 thru 29) 101585-01 101585-02 101585-03 101585-04 101585-05 101585-06 24 Bl.
94 Key No. Description (Quantity) Part Number ALP080 ALP105 ALP150 ALP210 ALP285 ALP399 35 Air Pressure Switch 80160762 101862-01 36 Air Pressure Switch Hose 7016039 7016046 37 Rubber Grommet, Condens.
95 Key No. Description (Quantity) Part Number ALP080 ALP105 ALP150 ALP210 ALP285 ALP399 42 Wiring Harness (Not Shown) 101454-01 43 MCBA Slide Out Assembly (Includes all parts shown) 101230-01 44 Contr.
96 Key No. Description (Quantity) Part Number ALP080 ALP105 ALP150 ALP210 ALP285 ALP399 30 Rubber Grommet, Gas Line 820SOL0001 101638-01 51 Jacket, Rear/Bottom Panel 101217-01 101217-02 101217-03 1012.
97 Key No. Description (Quantity) Part Number ALP080 ALP105 ALP150 ALP210 ALP285 ALP399 34 Flue T emp Sensor 101687-01 42 Wire Harness (Not Shown) 101454-01 72 Concentric V ent Collar with Viton Cap 1.
98 Key No. Description (Quantity) Part Number ALP080 ALP105 ALP150 ALP210 ALP285 ALP399 M iSCELLanEOUS P aRTS CaRTOn 101777-01 101777-02 101777-03 73 T emperature/Pressure Gauge 8056169 74 External Ga.
99 important Produc t Safety informa tion Refractory Ceram ic Fiber Product Warning : The Repair Parts list designates parts that contain refracto ry ceramic fibers (RCF).
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 oper ation of the boiler that is not in accordance with the boiler installation and operating instruction manual.
An important point after buying a device Burnham ALP399 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Burnham ALP399 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Burnham ALP399 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Burnham ALP399 you will learn all the available features of the product, as well as information on its operation. The information that you get Burnham ALP399 will certainly help you make a decision on the purchase.
If you already are a holder of Burnham ALP399, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Burnham ALP399.
However, one of the most important roles played by the user manual is to help in solving problems with Burnham ALP399. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Burnham ALP399 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
