Burnham Alpine ALP080 Owner's manual

1
VI. Water Piping and Trim
Supplemental Instructions
Recommended Circulator Models
Alpine™ Condensing High Efciency
Direct Vent Gas-Fired Hot Water Boiler
The information below supplements information contained in Installation, Operating and Service Instructions for Alpine™
Condensing High Efciency Direct Vent Gas-Fired Hot Water Boiler, Part No. 101602-01. Follow Supplemental Instructions and
details outlined below until directed otherwise.
WARNING
Prior to attempting any service on this boiler, read, understand and follow all instructions as outlined in
this supplement and also the Installation, Operating and Service Instructions which was provided with the
boiler.
GENERAL INFORMATION
These instructions contain supplemental revised information related to recommended circulator models for
Alpine™ boilers. Refer to Installation, Operating and Service Instructions manual for all other installation
instructions. Where applicable, substitute these instructions, paragraph for paragraph, for the information
outlined in the Installation, Operating and Service Instructions manual provided with the boiler.
102197-01R1-7/08
Boiler
Model
Boiler Supply
Connection,
Inch, FPT
Boiler Return
Connection,
Inch, FPT
Near-Boiler
Piping
Supply Pipe
Size, Inch
Near-Boiler
Piping
Return Pipe
Size, Inch
Flow, GPM
@ 25°F Temp.
Differential
Combined
Boiler & Piping
Loop Head
Loss, Ft.
* Recommended
Circulator
Make & Model
ALP080 1 1 1 1 5.8 10.3 Taco 0010 Grundfos UPS
15-58 FRC
ALP105 1 1 1 1 7.7 15.1 Taco 0014 Grundfos UPS
26-99 FC (second speed)
ALP150 1 1 1 1 11.0 13.1 Taco 0014 Grundfos UP
26-99 FC (rst speed)
ALP210 1 1 1¼ 1¼ 15.5 12.7 Taco 0014 Grundfos UP
26-99 FC (rst speed)
ALP285 1¼ 1¼ 1½ 1½ 21.5 13.0 Taco 0013 Grundfos UP
26-99 FC (third speed)
ALP399 1½ 1½ 2 2 30.2 12.0 Taco 1400-20 Grundfos UPS
32-80/2 F (second speed)
Notes:
* Circulator Models shown are not equipped with internal ow check valve (IFC).
When selecting Circulators with IFC contact Circulator Manufacturer for sizing information.
Near-Boiler Piping Size shown is based on 2 to 5.5 Ft/Sec. velocity range to avoid potential noise and pipe erosion.
Table 9 : Recommended Circulator Models for Alpine (ALP) Boilers Based on 25°F Temperature Differential
and Up to 75 ft. Equivalent Length Near-Boiler Piping

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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.
 Maintainingtheproperwaterowratethroughthe
heat exchanger of the Alpine boiler is crucial to ensure
trouble-free operation and long life. In addition to
causingoperationalissueswithintheboiler,insufcient
waterowthroughtheheatexchangercancause
damage and contribute to premature failure of the
boiler.Excessiveowthroughtheheatexchangercan
be just as problematic resulting in potential noise and
erosion.
NOTICE
Failure to maintain the ow through boiler within
specied limits could result in erratic operation or
premature boiler failure.
1. Near boiler piping must isolate ALP boiler from
system piping via closely spaced tees to insure
speciedowrangethroughboileranytimethe
boilerisring:
a. Theowratethroughtheboilerheatexchanger
and near-boiler piping is maintained by factory
recommended and installer supplied boiler
circulator.
Factory recommended range of circulators
based on factors often found in most hydronic
systems and shown in Table 9 will generate
an adequate ow rate and match combined
pressure drop through boiler heat exchanger
and near-boiler piping.
Table 9 lists recommended near-boiler piping
pipe diameter and circulator model for each
Alpine boiler model based on 25°F DT through
heat exchanger and up to 75 equivalent feet
near-boiler piping length. These selections are
adequate for most normal boiler installations.
However, installations operating at different DT
or with near-boiler piping length in excess of 75
equivalent feet may require different circulator
selection.
In such instances, the boiler heat exchanger
proper ow and head loss for different DT
may be selected from either Table 10 or “Alpine
Boiler Head Loss vs. Flow” Chart.
Next, near-boiler piping pipe diameter must
be sized based on 2 to 5.5 ft./sec. velocity
range, and near-boiler piping total equivalent
length determined based on the piping layout
andttingsandvalvesused,selectingtheir
equivalent length values from Table 11.
Thereafter, boiler heat exchanger head loss
and near-boiler piping total equivalent length
must be added, and an adequate circulator
selectedbasedonproperowandcombined
boiler heat exchanger head loss and near-boiler
piping total equivalent length.
b. Theowratethroughtheisolatedboilerloop
is completely independent oftheowrate
through the heating system loop(s).
c. Theowratethroughtheheatingsystemloop(s)
is controlled by installer sized/provided system
loop circulator(s).
d. This piping arrangement can be used in space
heating-only applications as well as space
heating with indirect water heater. See Figures
23A or 23B “ Near Boiler Piping – Heating
Only” and 24A or 24B “ Near Boiler Piping
– Heating Plus Indirect Water Heater”.

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Boiler
Model
Boiler
Supply
Connection,
Inch, FPT
Boiler
Return
Connection,
Inch, FPT
Minimum
Required Flow
(GPM)
@ 35°F DT
Boiler
Head Loss,
Ft.
@ 35°F DT
Required
Flow,
(GPM)
@ 30°F DT
Boiler
Head Loss,
Ft.
@ 30°F DT
Required
Flow,
(GPM)
@ 25°F
DT
Boiler
Head Loss,
Ft. @ 25°F
DT
Maximum
Required
Flow (GPM)
@ 20°F DT
Boiler
Head Loss,
Ft.
@ 20°F DT
ALP080 1 1 4.2 4.8 4.9 6.4 5.8 8.9 7.3 13.4
ALP105 1 1 5.5 7.0 6.4 9.3 7.7 12.8 9.6 19.1
ALP150 1 1 7.9 5.2 9.2 6.6 11.0 8.9 13.8 12.7
ALP210 1 1 11.1 5.4 12.9 7.1 15.5 9.8 19.4 14.4
ALP285 1¼ 1¼ 15.1 5.9 17.7 7.8 21.2 10.7 26.5 16.0
ALP399 1½ 1½ 21.5 6.1 25.1 7.9 30.2 10.8 37.7 15.9
Notes: Required Flow (GPM) = ** Output (MBH) * 1000 / 500 * DT
** Output (MBH) - Select Value for specic Boiler Model from Tables 2A or 2B
Using boiler antifreeze will result in higher uid density and may require larger circulators.
Table 10: Flow Range Requirement Through Boiler
Alpine Boiler Head Loss vs. Flow
80
105
150
210
285
399
0
2
4
6
8
10
12
14
16
18
20
0 5 10 15 20 25 30 35 40
Flow Rate (GPM)
Boiler Head Loss (Feet)

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Table 11: Fitting and Valve Equivalent Length
Copper Fitting and Sweat Valve
Equivalent Length (Ft)
Fitting or Valve
Description
Copper Pipe or Valve Size
1 1¼ 1½ 2
90° Elbow 2.5 3.0 4.0 5.5
45° Elbow 1.0 1.2 1.5 2.0
Tee (thru ow) 0.5 0.6 0.8 1.0
Tee (Branch ow) 4.5 5.5 7.0 9.0
Diverter Tee (typical) 23.5 25.0 23.0 23.0
Gate Valve 0.3 0.4 0.5 0.7
Globe Valve 25.0 36.0 46.0 56.0
Angle Valve 5.3 7.8 9.4 12.5
Ball Valve
(standard port) 4.3 7.0 6.6 14.0
Ball Valve (Full Port) 1.9 1.4 2.2 1.3
Swing Check Valve 4.5 5.5 6.5 9.0
Flow-Check Valve
(typical) 54.0 74.0 57.0 177.0
Buttery Valve 2.7 2.0 2.7 4.5
Threaded Fitting and Valve Equivalent Length (Ft)
Fitting or Valve
Description
Black Threaded Pipe or
Valve Size
1 1¼ 1½ 2
90° Elbow 2.6 3.5 4.0 5.2
Long Radius
Elbow (45° or 90°) 1.4 1.8 2.2 2.8
Tee (thru ow) 1.8 2.3 2.7 3.5
Tee (Branch ow) 5.3 6.9 8.1 10.0
Close Return Bend 4.4 5.8 6.7 8.6
Gate Valve (full open) 0.7 0.9 1.1 1.4
Globe Valve (full open) 30.0 39.0 46.0 59.0
Angle Valve (full open) 13.0 17.0 20.0 26.0
Swing Check Valve
(full open) 8.7 12.0 13.0 17.0
Flow-Check Valve (typical) 42.0 60.0 63.0 83.0
Table 11: Fitting and Valve Equivalent Length
(cont’d)
Example:
Assume that ALP105 will be installed in a heating
system along with the Alliance AL27SL indirect
water heater. A total of 15 ft of straight pipe will be
needed between the boiler and the heating system.
A total of 20 ft of straight pipe will be installed
between the boiler and the indirect water heater.
Copper ball valves, black threaded ttings and black
pipe are specied. Fittings are arranged as shown in
Figure 22A (Shaded Portion). The heating system
piping and indirect water heater piping are sized
based on 25° F temperature drop.
Fittings used in the Boiler Loop and equivalent
length of each tting are shown in Table below:
Fitting
Description Qty. Used
Fitting
Equivalent
Length, Ft
Total
Equivalent
Length
of Fittings, Ft
90° Elbow 5 2.6 13.0
Swing Check
Valve 1 8.7 8.7
Ball Valve
(Standard Port) 4 4.3 17.2
Tee (Thru Flow) 1 1.8 1.8
Total Equivalent Length of All Fittings,
Ft of Straight Pipe 40.7
Note: Unions, System Connection, Connection Tees
and factory- supplied ttings are ignored for above
calculations.
Total Boiler Loop Piping equivalent length is: 15 ft
(straight pipe) + 40.7 ft (straight pipe) = 55.7 ft of
straight pipe.
Reading Table 10 “ Recommended Circulator
Selection”, model ALP105, Taco 0014 model may be
selected as Boiler Loop circulator and will provide the
ow within range specied in Table 9 “Flow Range
Requirement Through Boiler”.
Fittings specied for the Indirect Water Heater Loop
Piping are arranged as shown in Figure 23A (Shaded
Portion).
All Indirect Water Heater Loop ttings and each tting
equivalent length are shown in Table below:
Fitting
Description Qty. Used
Fitting
Equivalent
Length, Ft
Total
Equivalent
Length
of Fittings, Ft
90° Elbow 8 2.6 20.8
Tee (Branch Flow) 2 5.3 10.6
Swing Check Valve 1 8.7 8.7
Ball Valve
(Standard Port) 2 4.3 8.6
Total Equivalent Length of All Fittings,
Ft of Straight Pipe 48.7
Total Indirect Water Heater Piping equivalent length is:
20 ft (straight pipe) + 48.7 ft (straight pipe) = 68.7 ft of
straight pipe.
Reading Table 10 “ Recommended Circulator
Selection”, for model ALP105 with Temperature Drop
of 25°F, Taco 0014 model may be selected as Indirect
Water Heater Loop circulator.

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C. Piping Standard Installation Requirements.
10. Low Water Cutoff (Required by some Codes)
– LWCO with harness and LWCO transformer are
available as optional components. Order Complete
Kit (Part No. 102097-01) when required.

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NOTES

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NOTES