Burnham Alpine ALP105 Service manual

101602-01R2-9/08 Price - $5.00
DNAGNITAREPO,NOITALLATSNI ROFSNOITCURTSNIECIVRES
™ENIPLA
YCNEICIFFEHGIHGNISNEDNOC TNEVTCERID RELIOBRETAWTOHDERIF-SAG
As an ENERGY STAR®Partner, Burnham Hydronics has determined that the Alpine™ Series meets the ENERGY
STAR® guidelines for energy efciency 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 additional information, consult a qualied installer, service agency or the
gas supplier. This boiler requires a special venting system. Read these instructions carefully before installing.

2
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 installed in Canada shall be made in accordance with the Canadian Electrical Code and/or local regulations.
The following terms are used throughout this manual to bring attention to the presence of hazards of various risk levels,
or to important information concerning product life.
The City of New York requires a Licensed Master Plumber supervise the installation of this product.
The Massachusetts Board of Plumbers and Gas Fitters has approved the Alpine™ Series boiler. See the Massachusetts Board of
Plumbers and Gas Fitters website, http://license.reg.state.ma.us/pubLic/pb_pre_form.asp for the latest Approval Code or ask
your local Sales Representative.
The Commonwealth of Massachusetts requires this product to be installed by a Licensed Plumber or Gas Fitter.
DANGER
Indicates an imminently hazardous situation
which, if not avoided, will result in death, serious
injury or substantial property damage.
CAUTION
Indicates a potentially hazardous situation which,
if not avoided, may result in moderate or minor
injury or property damage.
WARNING
Indicates a potentially hazardous situation which,
if not avoided, could result in death, serious injury
or substantial property damage.
NOTICE
Indicates special instructions on installation,
operation, or maintenance which are important
but not related to personal injury hazards.
DANGER
DO NOT store or use gasoline or other ammable vapors or liquids in the vicinity of this or any other
appliance.
If you smell gas vapors, NO NOT try to operate any appliance - DO NOT touch any electrical switch or use
any phone in the building. Immediately, call the gas supplier from a remotely located phone. Follow the gas
supplier’s instructions or if the supplier is unavailable, contact the re department.

3
WARNING
This boiler requires regular maintenance and service to operate safely. Follow the instructions contained
in this manual.
Improperinstallation,adjustment,alteration,serviceormaintenancecancausepropertydamage,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 boiler must be properly vented.
This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate
combustion and ventilation air.
The interior of the venting system must be inspected and cleaned before the start of the heating season
and should be inspected periodically throughout the heating season for any obstructions. A clean and
unobstructed venting system is necessary to allow noxious fumes that could cause injury or loss of life
to vent safely and will contribute toward maintaining the boiler’s efciency.
Installation is not complete unless a pressure relief valve is installed into the tapping located on left side
of appliance. - See the Water Piping and Trim Section of this manual for details.
This boiler is supplied with safety devices which may cause the boiler to shut down and not re-start
without service. If damage due to frozen pipes is a possibility, the heating system should not be left
unattended in cold weather; or appropriate safeguards and alarms should be installed on the heating
system to prevent damage if the boiler is inoperative.
This boiler contains very hot water under high pressure. Do not unscrew any pipe ttings nor attempt
to disconnect any components of this boiler without positively assuring the water is cool and has no
pressure. Always wear protective clothing and equipment when installing, starting up or servicing this
boiler to prevent scald injuries. Do not rely on the pressure and temperature gauges to determine the
temperature and pressure of the boiler. This boiler contains components which become very hot when
the boiler is operating. Do not touch any components unless they are cool.
Boilermaterialsofconstruction,productsofcombustionandthefuelcontainalumina,silica,heavymetals,
carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or harmful substances which can cause
death or serious injury and which are known to the state of California to cause cancer, birth defects and
other reproductive harm. Always use proper safety clothing, respirators and equipment when servicing
or working nearby the appliance.
Failure to follow all instructions in the proper order can cause personal injury or death. Read all instruc-
tions, including all those contained in component manufacturers manuals which are provided with the
boiler before installing, starting up, operating, maintaining or servicing.
Keep boiler area clear and free from combustible materials, gasoline and other ammable vapors or
liquids.
All cover plates, enclosures and guards must be in place at all times.
NOTICE
This boiler has a limited warranty, a copy of which is printed on the back of this manual. It is the responsibility
of the installing contractor to see that all controls are correctly installed and are operating properly when the
installation is complete.

4
Table of Contents
I. Product Description, Specifications
and Dimensional Data....................4
II. Pre-Installation...............................8
III. Unpacking Boiler ...........................9
IV. Venting......................................... 10
V. Condensate Disposal ....................29
VI. Water Piping and Trim .................31
VII. Gas Piping....................................46
VIII. Electrical.......................................49
IX. Boiler Stacking ............................. 56
X. Modular Installation ....................58
XI. System Start-up ............................66
XII. Operation.....................................72
XIII. Service and Maintenance..............84
XIV. Troubleshooting ...........................88
XV. Repair Parts.................................. 91
I. Product Description, Specications and Dimensional Data
Alpine™ Series boilers are condensing high efciency
gas-red direct vent hot water boilers designed for use
in forced hot water space or space heating with indirect
domestic hot water heating systems, where supply water
temperature does not exceed 210°F. These boilers have
special coil type stainless steel heat exchangers, constructed,
tested and stamped per Section IV ‘Heating Boilers’of
ASME Boiler and Pressure Vessel Code, which provide a
maximum heat transfer and simultaneous protection against
ue gas product corrosion. These boilers are not designed
for use in gravity hot water space heating systems or
systems containing signicant amount of dissolved oxygen
(swimming pool water heating, direct domestic hot water
heating, etc.).
Dimension Boiler Model
ALP080 ALP105 ALP150 ALP210 ALP285 ALP399
A - Inch
(mm) 12-9/16 (320) 14 (356) 19-11/16 (500) 23-15/16 (608) 21-13/16 (554) 28-7/8
(734)
B - Inch
(mm) 5-5/8 (142) 5-13/16 (147) 7-5/16 (185) 6-3/16 (157)
C - Inch
(mm) 7-5/16 (186) 14-1/8 (358) 13-1/16 (332)
D - Inch
(mm) 9-5/16 (237) 10-3/4 (273) 16-7/16 (417) 17-1/8 (435) 18 (456) 23-3/4 (602)
E - Inch
(mm) 5-15/16 (151) 12-1/4 (312) 15-13/16 (402)
Gas Inlet F
(FPT) 1/2” 3/4” 1”
Return G
(FPT) 1” 1-1/4” 1-1/2”
Supply H
(FPT) 1” 1-1/4” 1-1/2”
Condensate Drain J * * Factory Provided Socket End Compression Pipe Joining Clamp
for 3/4” Schedule 40 PVC Pipe
Boiler Two Pipe
CPVC/PVC Vent Connector
- Inch 3 x 3 3 x 4 4 x 4
Approx. Shipping Weight
(LBS) 137 155 182 206 256 304
Table 1: Dimensional Data (See Figures 1A & 1B)

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

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

7
Table 2A: Rating Data - Models ALP080 thru ALP399 (0 to 2000 Feet Elevation Above Sea Level)
Table 2B: Rating Data - Models ALP080 thru ALP399 (2001 to 7000 Feet Elevation Above Sea Level)
Alpine Series Gas-Fired Boilers
Model
Number *
Input
(MBH) ** Output
(MBH)
Net I=B=R
Ratings
Water (MBH)
AFUE
%
Thermal
Efciency
(%)
Combustion
Efciency (%)
Boiler Water
Volume
(Gal.)
Heat Transfer
Area (Sq. Ft.)
Min. Max.
ALP080 27 80 73 63 95 0.6 7.3
ALP105 35 105 96 83 95 0.7 9.1
ALP150 50 150 138 120 95 1.3 16.4
ALP210 70 210 194 169 95 1.7 21.8
ALP285 57 285 265 230 95 2.4 29.1
ALP399 80 399 377 328 94.1 94.5 3.4 41.8
*Add Sufx “N” for Natural Gas or Sufx “P” for LP Gas Models.
Notes: ** DOE Heating Capacity (ALP080 thru ALP285); Gross Output (ALP399)
Maximum Working Pressure, Water - 30 PSI Shipped from Factory (std.); 50 PSI - Optional
Maximum Allowable Temperature, Water - 210°F
Boilers are factory shipped as Natural Gas builds and have to be eld adjusted for LP gas application. Refer to ‘System Start-
Up Section of this manual for detailed procedure.
For elevations above 2000 Feet, ratings should be reduced at the rate of four percent (4%) for each 1000 Feet above sea level.
Alpine Series Gas-Fired Boilers
* Model
Number
Input
(MBH) ** Output
(MBH)
Net I=B=R
Ratings
Water (MBH)
AFUE
%
Thermal
Efciency
(%)
Combustion
Efciency (%)
Boiler Water
Volume
(Gal.)
Heat Transfer
Area
(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 80 399 377 328 94.1 94.5 3.4 41.8
*Add Sufx “N” for Natural Gas or Sufx “P” for LP Gas Models.
Notes: ** DOE Heating Capacity (ALP080 thru ALP285); Gross Output (ALP399)
Maximum Working Pressure, Water - 30 PSI Shipped from Factory (std.); 50 PSI - Optional (ALP080 thru ALP285)
Maximum Working Pressure, Water - 50 PSI Shipped from Factory (std.); (ALP399)
Maximum Allowable Temperature, Water - 210°F
Boilers are factory shipped as Natural Gas builds and have to be eld adjusted for LP gas application. Refer to ‘System Start-
Up Section of this manual for detailed procedure.
Ratings shown are for installations at sea level and elevations up to 2000 Feet. For elevations above 2000 Feet, ratings should be
reduced at the rate of four percent (4%) for each 1000 Feet above sea level.

8
WARNING
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.e. bleaches, cleaners, chemicals,
sprays, paint removers, fabric softeners, etc.) are
used or stored.
NOTICE
Due to the low water content of the boiler, mis-
sizing of the boiler with regard to the heating
system load will result in excessive boiler cycling
and accelerated component failure. Burnham
DOES NOT warrant failures caused by mis-sized
boiler applications. DO NOT oversize the boiler to
the system. Modular boiler installations greatly
reduce the likelihood of boiler oversizing.
A.Installation must conform to the requirements of the
authority having jurisdiction. In the absence of such
requirements, installation must conform to the National
Fuel Gas Code, NFPA 54/ANSI Z223.1, and/or CAN/
CSA B149.1 Installation Codes.
B. Appliance is design certied for installation on
combustible ooring. Do not install boiler on
carpeting.
C. Provide clearance between boiler jacket and
combustible material in accordance with local re
ordinance. Refer to Figure 2 for minimum listed
clearances from combustible material. Recommended
service clearance is 24 inches from left side, front, top
and rear of the boiler. Recommended front clearance
may be reduced to the combustible material clearance
providing:
1. Access to boiler front is provided through a door or
removable front access panel.
II. Pre-Installation
2. Access is provided to the condensate trap located
underneath the heat exchanger.
D. Install on level oor. For basement installation provide
a solid base such as concrete, if oor is not level or if
water may be encountered on oor around boiler. Floor
must be able to support weight of boiler, water and all
additional system components.
E. Protect gas ignition system components from water
(dripping, spraying, rain, etc.) during boiler operation
and service (circulator replacement, condensate trap,
control replacement, etc.).
F. Provide combustion and ventilation air in accordance
with applicable provisions of local building codes,
or: USA - National Fuel Gas Code, NFPA 54/ANSI
Z223.1, Air for Combustion and Ventilation;
Canada - Natural Gas and Propane Installation Code,
CAN/CSA-B149.1, Venting Systems and Air Supply for
Appliances.
WARNING
Adequate combustion and ventilation air must
be provided to assure proper combustion.
G. The boiler should be located so as to minimize the
length of the vent system. The PVC combustion
air piping, or the optional concentric vent piping,
containing integral combustion air inlet piping, must
terminate where outdoor air is available for combustion
and away from areas that may contaminate combustion
air. In particular, avoid areas near chemical products
containing chlorines, chloro/uorocarbons, paint
removers, cleaning solvents and detergents. Avoid
areas containing saw dust, loose insulation bers, dry
wall dust etc.
CAUTION
Avoid operating this boiler in an environment
where saw dust, loose insulation bers, dry wall
dust, etc. are present. If boiler is operated under
these conditions, the burner interior and ports
must be cleaned and inspected daily to insure
proper operation.

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
only by trained and skilled personnel from a
qualied service agency.
E. Move boiler to its permanent location.
Figure 2: Clearances To Combustible and Non-combustible Material

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 specied.
The use of thermal insulation covering pipe and ttings 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 interior wall penetrations.
Do not locate vent termination where exposed to prevailing winds. Moisture and ice may form on
surface around vent termination. To prevent deterioration, surface must be in good repair (sealed,
painted, etc.).
Do not locate vent termination where chlorines, chloro/uorocarbons (CFC’s), petroleum distillates,
detergents, volatile vapors or other chemicals are present. Severe boiler corrosion and failure will
result.
The use of cellular core PVC (ASTM F891) is prohibited.
Do not locate vent termination under a deck.
Do not reduce size of vent/combustion air pipe diameter.
When installing vent pipe through chimney, no other appliance can be vented into the chimney.
Do not allow low spots in the vent where condensate may pool.
A. Vent Guidelines Due to Removal of an Existing
Boiler
For installations not involving the replacement of an
existing boiler, proceed to Step B.
When an existing boiler is removed from a common
venting system, the common venting system is likely
to be too large for proper venting of the remaining
appliances. At the time of removal of an existing
boiler, the following steps shall be followed with each
appliance remaining connected to the common venting
system placed in operation, while the other appliances
remaining connected to the common venting system are
not in operation:
1. Seal any unused openings in the common venting
system.
2. Visually inspect the venting system for proper
size and horizontal pitch and determine there is no
blockage or restriction, leakage, corrosion, and other
deciencies which could cause an unsafe condition.
3. Insofar as is practical, close all building doors and
windows and all doors between the space in which
the appliances remaining connected to the common
venting system are located and other spaces of the
building. Turn on clothes dryers and any appliance
not connected to the common venting system.
Turn on any exhaust fans, such as range-hoods and
bathroom exhausts, so they will operate at maximum
speed. Do not operate a summer exhaust fan. Close
replace dampers.
4. Place in operation the appliance being inspected.
Follow the Lighting (or Operating) Instructions.
Adjust thermostat so appliance will operate
continuously.
5. Test for spillage at the draft hood relief opening
after ve (5) minutes of main burner operation. Use
the ame of a match or candle, or smoke from a
cigarette, cigar or pipe.
6. After it has been determined that each appliance
remaining connected to the common venting system
properly vents when tested as outlined above, return
doors, windows, exhaust fans, replace dampers and
any other gas burning appliance to their previous
conditions of use.
7. Any improper operation of the common venting
system should be corrected so the installation
conforms with the National Fuel Gas Code, NFPA
54/ANSI Z223.1. When resizing any portion of the
common venting system, the common venting
system should be resized to approach the minimum
size as determined using the appropriate tables in
Part II in the National Fuel Gas Code, NFPA 54/
ANSI Z223.1.
B. General Guidelines
1. Vent system installation must be in accordance
with National Fuel Gas Code, NFPA 54/ANSI
Z221.3 or applicable provisions of local building
codes. Contact local building or re ofcials about
restrictions and installation inspection in your area.