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INSTALLATION, OPERATING AND
SERVICE INSTRUCTIONS FOR
ALPINE™
CONDENSING HIGH EFFICIENCY
DIRECT VENT
GAS - FIRED HOT WATER BOILER
®
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. For assistance or ad
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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. All wiring on boilers installed in the USA shall be made in accordance with the National Electrical Code and/or local regulations. All wiring on boilers i
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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. installation and service must be performed only by an experienced, skilled, and knowledgeable installer or service agency This boile
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Table of Contents I. Product Description, Specifications VIII. Electrical ....................................... 49 and Dimensional Data.................... 4 IX. Boiler Stacking ............................. 56 II. Pre-Installation ............................... 8 X. Modular Installation .................... 58 III. Unpacking Boiler ........................... 9 XI. System Start-up ............................ 66 IV. Venting ..............................
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5 Figure 1a: alpine™ - Models aLP080 thru aLP210
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6 Figure 1B: alpine™ - Models aLP285 thru aLP99
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Table 2a: Rating Data - Models aLP080 thru aLP99 (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 (%) Water (MBH) (%) (Gal.) (Sq. Ft.) Min. Max. ALP080 16 80 73 63 95 0.6 7.3 ALP105 21 105 96 83 95 0.7 9.1 ALP150 30 150 138 120 95 1.3 16.4 ALP210 42 210 194 169 95 1.7 21.8 ALP285 57 285 265 230 95 2.4 29.1 ALP399 80 3
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ii. Pre-installation 2. Access is provided to the condensate trap located WaRning underneath the heat exchanger. if you do not follow these instructions exactly, D. Install on level floor. For basement installation provide a fire or explosion may result causing property a solid base such as concrete, if floor is not level or if damage or personal injury. water may be encountered on floor around boiler. Floor must be able to support weight of boiler, water and all additional system compo
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Figure 2: Clearances To Combustible and non-combustible Material iii. Unpacking Boiler D. Remove boiler from cardboard positioning sleeve on CaUTiOn shipping skid. Do not drop boiler. WaRning A. Move boiler to approximate installed position. installation of this boiler should be undertaken only by trained and skilled personnel from a B. Remove all crate fasteners. qualified service agency. C. Lift and remove outside container. E. Move boiler to its permanent location. 9
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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 insulation covering pipe and fittings is prohibited. Do not use a barometric damper, draft hood or vent damper with this boiler. The use of CPVC is required when venting in chase ways and through inte
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2. The Alpine™ is designed to be installed as a Direct See Table 6 for complete list of Burnham Vent Vent boiler. The air for combustion is supplied System Components. Use single wall thimble directly to the burner enclosure from outdoors and [Burnham Part No. 102180-01 (3”), 102181-01 (4”)] flue gases are vented directly outdoors (through wall when penetrating a combustible wall for vent only. or roof). 1. Horizontal vent pipe must maintain a minimum ¼ 3. The following combustion air/v
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Table : Vent System Components included with Boiler Quantity Part Vent System Components ALP080 & ALP105 ALP150 & ALP210 ALP285 & ALP399 Number (P/N 102189-01) (P/N 102189-02) (P/N 102189-03) 3” Schedule 40 PVC Tee Combustion Air/Vent Terminal 102190-01 2 1 --- 4” Schedule 40 PVC Tee Combustion Air/Vent Terminal 102190-02 --- 1 2 3” Stainless Steel Rodent Screens 102191-01 2 1 --- 4” Stainless Steel Rodent Screens 102191-02 --- 1 2 3” x 30” Schedule 40 CPVC Pipe 102193-01 1 1 --- 4” x 30” Sc
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Table : Vent/Combustion air Pipe Length 3” Combustion Air Pipe 4” Combustion Air Pipe 3” Vent Pipe 4” Vent Pipe Boiler (Equivalent Length) (Equivalent Length) (Equivalent Length) (Equivalent Length) Model 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. --- --- 21-7/8 In. 60 Ft. --- --- ALP150 --- --- 21-7/8 In. 60 Ft. 21-7/8 In. 60 Ft. --- --- ALP210 --- --- 21-7/8 In. 60 Ft. 21-7/8 In. 60 Ft. --- --- ALP285 --- ---
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Figure : Expansion Loop and Offset 6. Remove the Silicone flue sensor cap from the vent b. Clean all vent and combustion air pipe joints carton and press onto the two pipe vent system with primer and secure with transition cement, connector for CPVC/PVC sensor port. Remove (8 oz. bottle of primer and 8 oz. bottle of the tape holding the flue sensor and insert the flue transition cement supplied with boiler). Follow temperature sensor into the flue sensor plug until it the instructions p
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Figure : Field installation of Two Pipe Vent System Connector for CPVC/PVC Figure 5: near-Boiler Vent/Combustion air Piping 6. Install Rodent Screen and Vent Terminal (supplied 3. Horizontal combustion air pipe must maintain a with boiler), see Figure 8 for appropriate minimum ¼ inch per foot slope down towards configuration. terminal, when possible. If not, slope toward boiler. 7. Apply sealant between vent pipe and opening/ 4. It is strongly recommended to locate the combustion thimble
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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 penetrations require the use of roof flashing and storm collar that are not supplied with boiler. Vent Piping - Vertical 1. See Paragraph D for instructions on attaching the vent system connector to the boiler.
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Figure 8: Rodent Screen installation 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. CaUTiOn Vertical venting requires the use of roof flashing and a storm collar to prevent moisture from entering the structure. c. Install storm collar on ven
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7. Brace exterior piping if required. Vent Piping - Snorkel Combustion Air Piping - Vertical 1. See Paragraph D for instructions on attaching the vent system connector to the boiler. 1. See Paragraph D for instructions on attaching the vent system connector to the boiler. 2. Do not exceed maximum vent length. Refer to Table 7 for pipe diameters and allowable lengths. 2. Do not exceed maximum combustion air length. Refer to Table 7 for pipe diameters and allowable 3. Horizontal vent pipe m
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2. Remove the collar from the bag and set aside. 5. Install maximum vertical run of seven (7) feet of Schedule 40 PVC vent pipe. See Figure 11. 3. Locate and remove six mounting screws. 6. At top of vent pipe length install another PVC 90° 4. Position the Collar onto jacket combination rear/ elbow so that elbow leg is opposite the building’s bottom panel and insert collar inner stainless steel exterior surface. vent pipe into the heat exchanger vent outlet. 7. Install Rodent Screen and Com
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Figure 12: Field installation of Boiler Concentric Vent Collar codes. Contact local building or fire officials about 5. Provide and maintain vent pipe minimum clearances restrictions and installation inspection in your area. to combustible material. See Figure 2 and Table 10 for details. 2. Horizontal vent pipe must maintain a minimum ¼ inch per foot slope towards the boiler. 6. Provide minimum service clearance between boiler back and concentric vent exiting through outside 3. Use non
