Burnham Alpine ALP080 Installation, Operating And Service Instructions Download

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X. Modular

installation (continued)

Figure

: Three Boiler Modular W

iring Diagram

Internal Sage2.1 Multiple Boiler Control Sequencer

(Three Boilers Shown, T

ypical Connections for up to Eight Boilers)

Summary of Contents for Alpine ALP080

Page 1: ...y 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 additional information consult a qualified installer service agency or the gas supplier This b...

Page 2: ...te http license reg state ma us pubLic pl_products 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 ...

Page 3: ...ll be permanently mounted to the exterior of the building at a minimum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS 4 A final inspection by the state or local gas i...

Page 4: ... 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 fittings 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...

Page 5: ...Piping and Trim 66 D Gas Piping 66 E Electrical 76 F External Modular Boiler Controls 76 G Modular Boiler Operating Information 77 1 MajorFeatures 77 2 Operating Modes 79 3 Required Equipment and Setup 81 4 Adjusting Parameters 83 XI System Start up 86 XII Operation 92 A Major Features 92 B Operating Mode 96 1 Home Screen 96 2 Boiler Status Screen 97 C Controls Start up Checklist 98 D User Interfa...

Page 6: ...50 1 ALP210 1 ALP285 2 ALP399 2 ALP500 2 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 44 7 8 1140 B Inch mm 5 5 8 142 5 13 16 147 7 5 16 185 6 3 16 157 22 1 8 562 C Inch mm 7 5 16 186 14 1 8 358 13 1 16 332 29 737 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 39 11 16 1008 E Inch mm 5 15 16 151 12 1 4 312 15 13 16 402 29 3 8 752 Gas Inle...

Page 7: ... Figure 1A Alpine Models ALP080 thru ALP210 Floor Mounted I Product Description Specifications and Dimensional Data continued ...

Page 8: ... Figure 1B Alpine Models ALP080 thru ALP210 Wall Mounted I Product Description Specifications and Dimensional Data continued ...

Page 9: ... Figure 1C Alpine Models ALP285 thru ALP399 Floor Mounted Only I Product Description Specifications and Dimensional Data continued ...

Page 10: ...10 Figure 1D Alpine Model ALP500 Floor Mounted Only I Product Description Specifications and Dimensional Data continued ...

Page 11: ...on 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 Alpine Series Gas Fired Boilers Model Number Input MBH Output MBH Net I B R Ratings Water MBH AFUE Thermal Efficiency Combus...

Page 12: ...er Water Volume Gal Heat Transfer Area Sq Ft Min Max ALP150 38 113 104 90 95 1 3 16 4 ALP210 53 158 145 126 95 1 7 21 8 ALP285 68 204 188 163 95 2 4 29 1 Add Suffix F for Floor mounted Models or Suffix W for Wall mounted Models Notes DOE Heating Capacity ALP150 thru ALP285 Maximum Working Pressure Water 30 PSI Shipped from Factory std 50 PSI Optional Maximum Allowable Temperature Water 210 F Boile...

Page 13: ...bustion and ventilation air must be provided to assure proper combustion II Pre Installation Boiler Mounting F 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 conta...

Page 14: ...o locate and layout holes A and B These holes must be positioned on mounting stud centers if the boiler is installed on a framed wall Make sure that the horizontal centerline of these holes is level Holes C and D may also be drilled at this time or after the boiler is hung on the wall If the 5 16 x 2 lag screws are used drill 3 16 pilot holes g An alternate way to locate mark holes A and B is to u...

Page 15: ... Figure 2A Clearances To Combustible and Non combustible Material Floor Standing Figure 2B Clearances To Combustible and Non combustible Material Wall Mounted II Pre Installation Boiler Mounting continued ...

Page 16: ...press the gasket lightly down Continue peeling of protective paper and positioning the gasket in place while insuring edge alignment Once the gasket is fully in place and edges are aligned press the gasket firmly in position o Set the panel with gasket aside p See Section IV Venting paragraph Field Installation of CPVC Vent Pipe Wall Mounted Boiler Builds for instructions on attaching the vent sys...

Page 17: ...r from cardboard positioning sleeve on shipping skid WARNING Installation of this boiler should be undertaken only by trained and skilled personnel from a qualified service agency E Move boiler to its permanent location Figure 2D Bottom Mounting Bracket Installation Boiler Wall Mounting Figure 2E Access Panel and Gasket Installation II Pre Installation Boiler Mounting continued ...

Page 18: ...ure 3 Vent terminals must be at least 1 foot from any door window or gravity inlet into the building Maintain the correct clearance and orientation between the vent and air intake terminals The vent and air intake terminals must be at the same height and their center lines must be spaced apart 12 minimum Locate air intake termination on the same wall as the vent termination if possible WARNING Fai...

Page 19: ...ncludes separate stainless steel vent pipe and PVC galvanized steel air intake pipe terminating thru sidewall with individual penetrations for the vent and air intake piping and separate terminals 8 13 8A 8B C Optional Snorkel thru sidewall Same as above but separate snorkel type terminals 10 13 Vertical Vertical thru roof The system includes separate stainless steel vent pipe and PVC galvanized s...

Page 20: ... wall away from the prevailing wind Reliable operation of this boiler cannot be guaranteed if the terminal is subjected to winds in excess of 40 mph Air intake terminal must not terminate in areas that might contain combustion air contaminates such as near swimming pools For sidewall venting the minimum horizontal distance between any adjacent individual module boiler vent terminations is twelve 1...

Page 21: ...ity ALP080 ALP105 Vertical Roof Termination ALP150 ALP210 Vertical Roof Termination ALP285 thru ALP500 Vertical Roof Termination 3 Schedule 40 PVC Coupler N A Supplied by Others 1 N A N A 4 Schedule 40 PVC Coupler N A 1 1 3 Schedule 40 PVC 90 Elbow 2 N A N A 4 Schedule 40 PVC 90 Elbow N A 2 2 3 Schedule 40 CPVC Pipe x ft min horizontal run 1 N A N A 4 Schedule 40 CPVC Pipe x ft min horizontal run ...

Page 22: ...ivalent length of vent combustion air pipe total length of straight pipe plus equivalent length of fittings Maximum vent combustion air lengths are listed in Table 7 Do not exceed maximum vent combustion air lengths Table 6 lists equivalent lengths for fittings Do not include vent combustion air terminals in equivalent feet calculations See Combustion Air Vent Equivalent Length Work Sheet c The ve...

Page 23: ...Venting continued 2 L 5 6 MIN 6 MIN 5 4 4 2 LONG RUN OF PIPE CHANGE OF DIRECTION VERTICAL OR HORIZONTAL LOOP HORIZONTAL ONLY TOP VIEW OFFSET L L L L LOOP LENGTH L L L RESTRAINT RESTRICTS MOVEMENT HANGER ALLOWS MOVEMENT KEY Pipe Dia In Length of Straight Run Ft Loop Length L In 3 20 50 30 61 40 70 50 79 60 86 4 20 56 30 69 40 80 50 89 60 98 ...

Page 24: ... Air Vent 90 elbow s PVC Supplied 30 straight CPVC Quantity x 5 equiv ft a Length ft 2 5 x 1 2 5 equiv ft a 45 elbow s PVC Supplied 90 elbow CPVC Quantity x 2 5 equiv ft b Quantity 1 x 5 5 equiv ft b Straight pipe PVC 90 elbow s PVC Length ft x 1 equiv ft c Quantity x 5 equiv ft c 45 elbow s PVC Quantity x 2 5 equiv ft d Straight pipe PVC Length ft x 1 equiv ft e Total a b c equiv ft Total a b c d...

Page 25: ...llar vent opening and slide down with a slight twisting motion until the pipe lower end is firmly inserted into female end of factory installed vent connector 90 Elbow b Secure the pipe by tightening the metal strap worm screw i The CPVC 30 long straight pipe may be cut to accommodate desired vent configuration If the CPVC 30 straight pipe needs to be cut into two pieces to accommodate desired ven...

Page 26: ...tall Rodent Screen and Combustion Air Terminal supplied with boiler see Figure 9 for appropriate configuration Apply sealant between vent pipe and opening to provide weather tight seal b Optional Two Pipe Snorkel Termination Refer to Figures 7 9 and 10 This installation will allow a maximum of seven 7 feet vertical exterior run of the vent combustion air piping to be installed on the CPVC PVC hori...

Page 27: ...ect Vent Vertical Terminations Figure 10 Direct Vent Optional Sidewall Snorkel Terminations i Vent Piping Install fire stops where vent passes through floors ceilings or framed walls The fire stop must close the opening between the vent pipe and the structure Whenever possible install vent straight through the roof Refer to Figures 11 and 12 Size roof opening to maintain minimum clearance of 1 fro...

Page 28: ...w accumulation Provide brace as required Install storm collar on combustion air pipe immediately above flashing Apply Dow Corning Silastic 732 RTV Sealant between combustion air pipe and storm collar to provide weather tight seal Install Rodent Screen and Combustion Air Terminal supplied with boiler see Figure 9 for appropriate configuration Brace exterior piping if required WARNING All CPVC suppl...

Page 29: ...6 or equivalent for the vent collar Air inlet piping sections are sealed with any general purpose silicone sealant such as GE RTV102 PVC air inlet piping sections are connected with PVC cement d Longitudinal welded seams should not be placed at the bottom of horizontal sections of exhaust pipe e Do not drill holes in vent pipe f Do not attempt to mix vent components of different vent system manufa...

Page 30: ...the terminal before inserting it into the last piece of pipe Orient the terminal so that the seam in the terminal is at 12 00 Smooth the silicone over the seam between the terminal and the last piece of pipe applying additional silicone if necessary to ensure a tight seal Allow the silicone to cure per the silicone manufacturer s instructions before operating the boiler ii Combustion Air Terminati...

Page 31: ...5 mm See Note 2 101492 01 Support Elbow with Chimney Chase Bracket 80 125 mm 8 5 See Note 3 101498 01 Hanger Wall Bracket 80 125 mm 101909 01 Locking Clamp 80 125 mm 101548 01 90 Elbow Long Radius 100 150 mm 8 0 101549 01 45 Elbow Long Radius 100 150 mm 3 0 101550 01 1 Cut To Length Extension 500 mm 19 1 2 100 150 mm 1 63 Can be cut 101551 01 Cut To Length Extension 1000 mm 39 100 150 mm 3 25 Can ...

Page 32: ...ical wires Start at vent connector at boiler and work towards vent termination b Do not exceed maximum Concentric vent length Refer to Table 9 c If additional concentric vent piping is needed i Concentric Vent Cut To Length Extension pipes identified in Table 10 CAN BE CUT to required length when used as an extension These pipes have plain male end and beaded female end Always cut the pipe from pl...

Page 33: ...wn gasket in the boiler vent collar with a few drops of water ii Push the male end of the first fitting 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 4 above is covered On other fittings the bead on the male pipe will be bottom out on the collar see Figure 19 iii The male end of cuttable fittings must...

Page 34: ...al Wall Terminal will extend past outer wall surface by 4 80 125 mm or 5 100 150 mm See Figure 20 Horizontal Concentric Venting iv Install the Horizontal Wall Terminal Cut a 5 diameter hole through the exterior wall opening for 80 125 mm concentric vent or 6 for 100 150 mm at the planned location of the horizontal terminal Measure dimension L from exterior wall outer surface to the end of the last...

Page 35: ...he terminal is evenly engaged into the gasket all around then push the termination male end inside boiler concentric vent collar or the last section of the vent pipe until the mark see Step v is no longer visible Re install locking band clamp onto the joint to secure the terminal to the collar or the last section of the vent pipe 5 Vertical Vent Termination a Standard Concentric Termination Refer ...

Page 36: ...collar to the end of the last fitting as shown in Figure 25 Add 1 to distance H Carefully mark this length on the pipe as shown in Figure 26 Cut the outer pipe only at the point marked in Step e using aviation shears a hacksaw or an abrasive wheel cutter Be careful to cut the pipe square De burr the cut end with a file or emery cloth Place a mark on the plastic inner pipe 3 8 beyond the end of the...

Page 37: ...ry chimney The Chimney chase Support Elbow with attached Mounting Bracket is used at the base of the chimney Refer to Table 10 Concentric Vent Components for details Slip the elbow over the M10 x 35 screw in the support bracket Determine the desired vertical location of the support elbow in the chimney and mark the location of the pin positioned on the back of the support bracket onto the chimney ...

Page 38: ...hes 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 maxi mum speed Do not operate a summer exhaust fan Close fireplace dampers 4 Place in operation the appliance being inspected Follow the Lighting or Operating Instructions Adjust thermo stat so appliance will operate continuously 5 Test ...

Page 39: ...must be filled up with water prior to boiler start up and before connecting any condensate line to the boiler to insure combustion products cannot escape from operating boiler To fill the trap inject water in the amount of 1 cup 8 fluid ounces through condensate trap stub opening Do not overfill the trap 6 If any additional condensate drain line is needed construct the extension from PVC or CPVC S...

Page 40: ...40 Figure 29 Condensate Trap and Drain Line V Condensate Disposal continued ...

Page 41: ...e protected from water dripping spraying rain etc during appliance operation and service circulator replacement etc Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components and can lead to boiler failure U S Boiler s Standard Warranty does not cover problems caused by oxygen contamination of boiler water or scale lime build up caused by frequent addition of wat...

Page 42: ...le 1 x 1 x NPT black tee x NPT black reducing bushing and Temperature Pressure Gauge b Mount the nipple into 1 boiler supply tapping see Figures 1B and 1D then install the tee onto the nipple making sure branch outlet is in horizontal plane and facing the boiler front c Install x NPT black reducing bushing into the tee branch then put in Temperature Pressure Gauge B Piping System To Be Employed Al...

Page 43: ...3 8 12 7 ALP210 1 1 11 1 5 4 12 9 7 1 15 5 9 8 19 4 14 4 ALP285 1 1 15 1 5 9 17 7 7 8 21 2 10 7 26 5 16 0 ALP399 1 1 21 5 6 1 25 1 7 9 30 2 10 8 37 7 15 9 ALP500 1 1 27 0 6 8 31 5 8 8 37 8 12 0 47 2 17 4 Notes Required Flow GPM Output MBH x 1000 500 x DT Output MBH Select Value for specific Boiler Model from Tables 2A or 2B Using boiler antifreeze will result in higher fluid density and may requir...

Page 44: ... same as through boiler and fall within limits specified in Table 11 b Pressure drop through entire system must be known added to pressure drop through boiler and a circulator selected to provide required flow at total calculated pressure drop c It is often very difficult to accurately calculate the pressure drop through the system d In replacement installations it may be nearly impossible to get ...

Page 45: ...amage Before connecting the boiler insure the system is free of impurities grease sediment construction dust sand copper dust flux and any residual boiler water additives Flush the system thoroughly and repeatedly if needed with clear water mixed with concentrated rinse agent to remove these contaminants completely Iron oxide red oxide sludge Fe2 O3 is produced during oxygenation To minimize any o...

Page 46: ... and Trim continued CAUTION It is the installers responsibility to select pumps and boiler piping configurations that provide the proper flow rates and performance for the boiler and indirect water heater Refer to Table 12 for recommended Boiler Loop Circulator ...

Page 47: ...ater Piping and Trim continued CAUTION It is the installers responsibility to select pumps and boiler piping configurations that provide the proper flow rates and performance for the boiler and indirect water heater Refer to Table 12 for recommended Boiler Loop Circulator ...

Page 48: ...ows in circulator zone systems through zones that are not calling for heat 8 Isolation Valves Strongly recommended Isolation valves are useful when the boiler must be drained as they will eliminate having to drain and refill the entire system 9 Drain Valve Required Drain valve is packaged loose with boiler and must be installed in the location shown in Figure 30 Factory Supplied Piping and Trim In...

Page 49: ...49 Figure 33 Isolation of the Boiler From Oxygenated Water with A Plate Heat Exchanger VI Water Piping and Trim continued ...

Page 50: ... 0 5 psig or Less Inlet Pressure 0 5 PSI or less 0 5 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 0 622 172 118 95 81 72 65 60 56 52 50 0 824 360 247 199 170 151 137 126 117 110 104 1 1 049 678 466 374 320 284 257 237 220 207 195 1 1 380 1392 957 768 657 583 528 486 452 424 400 1 1 610 2085 1433 1151 985 873 791 728 677 635 600 2 2...

Page 51: ... 532 490 456 427 404 2 2 067 2703 1858 1492 1277 1131 1025 943 877 823 778 2 2 469 4308 2961 2377 2035 1803 1634 1503 1399 1312 1239 3 3 068 7615 5234 4203 3597 3188 2889 2658 2472 2320 2191 1 CFH of LP Gas is approximately equal to 2 5 MBH contact your gas supplier for the actual heating value of your gas Table 15 Equivalent Lengths of Standard Pipe Fittings Valves Nominal Pipe Size Inc Inside Di...

Page 52: ...piping as follows a Locate and remove either NPT x 6 long black nipple and NPT external gas shutoff valve ALP080 thru ALP210 or NPT x 6 long black nipple and NPT external gas shutoff valve ALP285 thru ALP500 b Feed the appropriate nipple through factory installed jacket left side panel grommet refer to Figure 1A or 1B for gas supply connection identification and screw the nipple into boiler gas va...

Page 53: ...witches 1 The low gas pressure switch must be reset after the boiler is piped to the gas supply and before it is fired 2 For the low and high gas pressure switches proper operation the boiler inlet gas pressure must be within 4 5 w c to 13 5 w c range 3 The gas pressure can be measured at the gas valve inlet pressure port Refer to Figure 34B 4 If either pressure switch is tripped it must be manual...

Page 54: ...reen Ground connection DANGER Positively assure all electrical connections are unpowered before attempting installation or service of electrical components or connections of the boiler or building Lock out all electrical boxes with padlock once power is turned off WARNING Failure to properly wire electrical connections to the boiler may result in serious physical harm Electrical power may be from ...

Page 55: ...oided Avoid placing the sensor near potential sources of electrical noise such as transformers power lines and fluorescent lighting Wire the sensor to the boiler using 22 gauge or larger wire As with the sensor the sensor wiring should be routed away from sources of electrical noise Where it is impossible to avoid such noise sources wire the sensor using a 2 conductor UL Type CM AWM Style 2092 300...

Page 56: ...56 VIII Electrical continued ...

Page 57: ...57 VIII Electrical continued Figure 35 Wiring Connections Diagram ...

Page 58: ...58 Figure 36 Ladder Diagram VIII Electrical continued ...

Page 59: ...ure 37A Modified Wiring For DHW Priority When Using Low Flow Circulator Piped Off System Header Heating with Central Heating Circulators Plus Alternately Piped Indirect Water Heater VIII Electrical continued ...

Page 60: ...T POWER SUPPLY 120 60 1 FIELD INSTALLED 40VA TRANSFORMER SEE NOTE 2 WIRE 24V THERMOSTATS W HEAT ANTICIPATOR SET AT 0 9 AMPS 40VA REQ D FOR EVERY 3 ZONE VALVES 2 WIRE 24V THERMOSTATS W HEAT ANTICIPATOR SET AT 0 5 AMPS 40VA REQ D FOR EVERY 4 ZONE VALVES 2 WIRE 24V THERMOSTATS W HEAT ANTICIPATOR SET AT 0 3 AMPS 40VA REQ D FOR EVERY 4 ZONE VALVES WHITE ROGERS 1361 102 ZONE VALVES CHECK FOR CROSS PHASI...

Page 61: ...cket two upper holes with corresponding side panel lower dimples The remaining lower bracket hole must align with a matching bottom boiler left side panel top positioning dimple Once bracket holes and side panel dimple alignment is verified attach the bracket to top and bottom boiler left side panels with the mounting screws 5 Repeat above procedure to install second Stacking Boiler Attachment Bra...

Page 62: ... stackable boiler combination Figure 38 Stacking Boiler Attachment Bracket Placement 3 Water Piping and Trim Follow instructions in Section VI Water Piping and Trim of the manual for system piping and boiler secondary piping selection sizing based on combined heating capacity and or gross output of the selected stackable boiler combination Follow instructions of Section VI Water Piping and Trim fo...

Page 63: ...le vertical vent pipes may be piped through a common conduit or chase so that one roof penetration may be made The minimum horizontal distance between any adjacent individual module boiler roof vent terminations is one 1 foot 2 PVC Pipe Air Intake Piping a Modular PVC air intake piping is shown in Figure 39 b Each individual module boiler must have own combustion air intake pipe and combustion air...

Page 64: ...64 Figure 39 Modular Boiler Direct Vent Termination X Modular Installation continued ...

Page 65: ...65 Figure 40 Modular Boiler Concentric Vent Termination X Modular Installation continued ...

Page 66: ...iler piping system specific details c Selection criteria for individual module boiler space heating and or DHW circulators 2 For installations where indirect domestic hot water heater is combined with space heating when sizing an indirect water heater circulator compare the specified flow range through an Alpine model boiler to an indirect water heater Alliance SL model coil flow rate required to ...

Page 67: ... 1of 2 X Modular Installation continued NOTICE Installing a low water cutoff in the system piping of modular boilers is strongly recommended and may be required by Local Codes B Keep this distance as short as practical C At least 18 of straight pipe for Conventional Air Scoop ...

Page 68: ...iler Water Piping w Domestic Hot Water Heater Page 2 of 2 X Modular Installation continued NOTICE Installing a low water cutoff in the system piping of modular boilers is strongly recommended and may be required by Local Codes ...

Page 69: ...r Page 1 of 2 X Modular Installation continued CAUTION It is the installers responsibility to select pumps and boiler piping configurations that provide the proper flow rates and performance for the boiler and indirect water heater Refer to Table 12 for recommended Boiler Loop Circulator ...

Page 70: ...r Page 2 of 2 X Modular Installation continued CAUTION It is the installers responsibility to select pumps and boiler piping configurations that provide the proper flow rates and performance for the boiler and indirect water heater Refer to Table 21 for recommended Boiler Loop Circulator ...

Page 71: ...7 36 Taco 1400 45 Grundfos UPS 32 80 2 max speed 42B NOTES Note 1 Required Alliance SL Coil Flow Rate exceeds Max Allowable Flow Rate thru Boiler this Boiler Alliance SL combination may result in boiler heat exchanger erosion and noise Note 2 Required Alliance SL Coil Flow Rate is below Min Required Flow Rate thru Boiler this Model can only be installed as separate heating zone off system header s...

Page 72: ...L70 6 10 SL119 14 17 0 27 0 Taco 1400 45 Grundfos UPS 32 80 2 max speed 42B Note 3 ALP399 1 1 2 1 1 2 2 2 37 7 30 2 21 5 SL27 6 9 NA Not Recommended 41A Note 2 SL35 6 9 SL50 6 9 5 SL70 6 10 SL119 14 17 0 ALP500 1 1 2 1 1 2 2 2 47 2 37 8 27 0 SL27 6 9 41A Note 2 SL35 6 9 SL50 6 9 5 SL70 6 10 SL119 14 17 0 NOTES Note 1 Required Alliance SL Coil Flow Rate exceeds Max Allowable Flow Rate thru Boiler t...

Page 73: ...73 X Modular Installation continued Figure 43 Three Boiler Modular Wiring Diagram Internal Sage2 1 Multiple Boiler Control Sequencer Three Boilers Shown Typical Connections for up to Eight Boilers ...

Page 74: ... the Tekmar 265 Control and each boiler s Sage2 1 Control The boiler s and system supply water temperature will be reset together to maintain the input that is needed to the system When a call for Indirect Hot Water is generated to the Tekmar 265 the control will de energize the zone pump control ZC terminal energize the Indirect pump and modulate the boiler firing to establish a setpoint temperat...

Page 75: ...ut to the system main to satisfy the desired reset water temperature in the main established by the Tekmar 264 Control When a call for Indirect Hot Water is generated to the Tekmar 264 the control will de energize the zone pump control ZC terminal energize the Indirect pump and sequentially fire the boilers to establish a setpoint temperature in the main for the Indirect Heater using Priority The ...

Page 76: ...boiler internal wiring details high and low voltage connections X Modular Installation continued Each individual module boiler must be provided with own fused disconnect and own service switch Installmodularboilerwiringinaccordancewithrequirementsof authorityhavingjurisdiction Inabsenceofsuchrequirements followtheNationalElectricCode NFPA70and orCSAC22 1 Electric Code F External Modular Boiler Con...

Page 77: ...ed last 3 2 1 To equalize the run time the sequencer automatically rotates the Lead boiler after 24 hours of run time e Customized Sequences Normally boilers are started and stopped in numerical order However custom sequences may be established to optimize the heat delivery For example in order to minimize boiler cycling a large boiler may be selected to run first during winter months and then sel...

Page 78: ...r fast load change example When water temperature is below the setpoint by more than the Diff Below setting for longer than 2 minutes and firing rate is at the High Fire Limit the second boiler is started and both modulate in unison to satisfy the heat load iii Start Last Lag Boiler slow load change example When boiler firing rate has been next to the High Fire Limit for longer than 20 minutes the...

Page 79: ...tatus shown on the Sequencer Status Screen provides connected start sequence and firing rate status information for all connected boiler addresses The boiler number is underlined if the boiler is running and blinks if the boiler has the start sequence in progress For example the status for boiler address 1 is provided as follows Boiler Status Display 1 Boiler 1 is connected 1 Blinking underline bo...

Page 80: ...ng On Leave The Slave boiler has left the network to service a DHW demand Recovering The slave boiler is in the process of returning to the network For example the slave boiler is in the post purge state Disabled The slave boiler has a lockout condition and is unable to become available to the Sequencer Master c Sequencer Alarm This alarm shown in Figure 47 is active when the slave boiler has lost...

Page 81: ...er Refer to piping diagram Figures 41A and 42A for installation location and Figure 48 or 49 for installation detail b RJ45 Splitters P N 103092 01 RJ45 Splitters are required for installing communications between three or more boilers When two boilers are connected the splitter is not required c Ethernet Cables Ethernet cables are used to connect the boiler network together These are standard str...

Page 82: ...wer to All Boilers 4 Set Unique Boiler Addresses Assign all boilers a unique Boiler Address using any number from 1 through 8 WARNING When two boiler s addresses are the same undesirable simultaneous operation occurs 5 Enable 1 Boiler Master Enable only one Sage2 Control s Sequencer Master WARNING When more than one Sequencer Master is enable erratic behavior will result 6 Power Down All Boilers 7...

Page 83: ...er to respond to rapid load changes Press Sequencer Slave button to access the following parameters Factory Setting Range Choices Parameter and Description None 1 8 Boiler Address Each boiler must be given a unique address When Normal slave selection order is used the boiler address is used by the Master Sequencer as the boiler start order The boiler address is also the Modbus Address when a build...

Page 84: ...n Never Pump is disabled and not shown on status screen Primary Loop Piped IWH Pump Runs during domestic hot water call for heat Domestic Hot Water Priority enable disable does not affect pump operation Boiler Piped IWH Pump Runs during domestic hot water call for heat Pump is forced off during a central heat call for heat when Domestic Hot Water Priority disabled is selected and when Domestic Hot...

Page 85: ...emand Any demand DHW Pump Primary Loop Piped IWH Never Explanation This piping arrangement permits the system pump to run or not run when there is a domestic hot water call for heat Domestic hot water priority is optional It is permissible for the domestic and system pumps to run at the same time The boiler pump must run for every call for heat Sequencer Master Boiler 1 Boiler 2 Wiring locations T...

Page 86: ...p 2 Alpine gas valves have inlet and outlet pressure taps with built in shut off screw Turn each screw from fully closed position three to four turns counterclockwise to open taps Connect manometers to pressure taps on gas valve NOTICE If it is required to perform a long term pressure test of the hydronic system the boiler should first be isolated to avoid a pressure loss due to the escape of air ...

Page 87: ...between the upper and lower limits shown on the rating plate with all gas appliances on and off WARNING The outlet pressure for the gas valve has been factory set and requires no field adjustment This setting is satisfactory for both natural gas and propane Attempting to adjust the outlet pressure may result in damage to the gas valve and cause property damage personal injury or loss of life K Per...

Page 88: ...88 Alpine Series Lighting and Operating Instructions Figure 51 Lighting Instructions XI System Start up continued ...

Page 89: ...fe The qualified service agency is responsible for proper conversion of these boilers The conversion is not proper and complete until the operation of the converted appliance is checked as specified in this manual WARNING These instructions include a procedure for adjusting the air fuel mixture on this boiler This procedure requires a combustion analyzer to measure the CO2 or Oxygen and Carbon Mon...

Page 90: ...r the burner lights force the burner to high fire Allow the boiler to operate for approximately 5 minutes before taking combustion readings Figure 53 Dungs Gas Valve Detail Table 24 Number of Clockwise Throttle Screw Turns for LP Conversion Boiler Model Gas Valve Throttle Screw Turns at Altitude Range 0 7000 Ft ALP080 Dungs GB 055 NPT 2 ALP105 4 ALP150 3 ALP210 4 ALP285 Dungs GB 057 NPT 4 ALP399 D...

Page 91: ...s and must never be adjusted in the field The gas valve outlet pressure is the same for both natural gas and propane Make sure that all adjustments are made with the throttle not the pressure regulator Attempting to adjust the pressure regulator will result in damage to the gas valve and may cause property damage personal injury or loss of life 7 Perform a combustion test Refer to Paragraph K abov...

Page 92: ... Service rated relay outputs are wired to a line voltage terminal block for easy field connection Simple parameter selections allow all three pumps to respond properly to various system piping arrangements including either a boiler or primary piped indirect water heater 4 Circulator Exercising Circulators are automatically run for a 20 second exercise period after not being used for longer than 7 ...

Page 93: ...equence Control as the priority even if there is no current Call For Heat The boilers are slaves waiting to fired based on the Sequence Master s demand inputs b Domestic Hot Water Adomestichotwaterdemandisreceivedbywiring a demand contact to the low voltage terminal strip DHW Temp Switch terminals The boiler responds to a domestic hot water demand with a domestic hot water setpoint and pump settin...

Page 94: ...at setpoint will automatically adjust downwards as the outdoor temperature XII Operation continued increases When the water temperature is properly matched to home heating needs there is minimal chance of room air temperature overshoot Excessive heat is not sent to the room heating elements by overheated supply water temperature maintained at High Limit setting water Reset control saves energy by ...

Page 95: ...ay the Sage2 1 shuts down the boileranddelaysrestart Iftheinvertedtemperature is detected more than five times the boiler manual XII Operation continued reset Hard Lockout is set This condition is the resultofincorrectlyattachingthesupplyandreturn piping d External Limit An external limit control can be installed between terminals 11 and 12 on the low voltage terminal strip Besuretoremovethejumper...

Page 96: ...gh to cause flue gas condensation f Boiler Status When there is no call for heat this line shows standby Table 28 shows each possible status and the control action taken during the condition XII Operation continued Figure 54 Home Screen Status Control Action Initiate Power up Standby Delay This state is entered when a delay is needed before allowing the burner control to be available and for senso...

Page 97: ...lays the cause of the rate limit Rate Limits High Supply Temperature Limit High Differential Temperature Limit High Stack Temperature Limit Minimum Modulate normal start stop sequence Forced Modulation normal start stop sequence Burner Fault Rate Lockout etc Burner Control Rate normal start stop sequence Manual Firing Rate User selection XII Operation continued Figure 55 Status Screen Boiler 1 Rat...

Page 98: ...r your heating system Refer to Section E Adjusting Parameters Pump Setup Menu for additional information Boiler Pump Domestic Pump 5 Contractor Setup Contractor Name Enter your contact information name address and phone number on this screen In the event of a fault or the need to adjust a setting the display will direct the homeowner to you Address Phone 6 Manual Control Manual Speed Control Use t...

Page 99: ...e is a problem with the sensor Screen Links Information The i screen link symbol indicates the presence of an Information screen These screens explain screen content and provide other helpful information Next screen The or screen link symbol indicates the presence of additional screens Back to Previous This button selects the previous screen or allows the user to leave this display level and retur...

Page 100: ...nput open contact refer to Figure 36 Ladder Diagram Interlock input terminal J5 1 For example this illustration depicts the Float Switch contact as open This indicates that boiler s condensate float switch has detected high water level and it s contact is open causing the boiler to stop Note Interlock input limit items are wired in series Items down stream of the open limit will also appear as ope...

Page 101: ...rd is 76 and press the return arrow to close the keypad Press the Save button v Press the Adjust button to enter Adjustment mode b Editing Parameters is accomplished as follows Value to be edited Use the buttons to edit a value While editing a value it will blink until it has been accepted or cancelled as described below A value is also cancelled by leaving the screen without accepting the value A...

Page 102: ...ed to the boiler the sensor is not monitored for faults Installed Outdoor Sensor is installed and monitored for faults Note Enabling Frost Protection Warm weather shutdown or Outdoor Air Reset functions will automatically install the outdoor sensor If you choose to disable these features and not use the outdoor sensor press the Not Installed selection to remove the outdoor sensor from fault monito...

Page 103: ...um Modulation fan speed setting to limit the boiler output accordingly See Table 30 Absolute Max to Minimum Modulation Domestic Hot Water DHW Max Modulation This parameter defines the highest modulation rate the Sage2 1 control will go to during a central heat Domestic Hot Water call for heat If the rated input of the indirect water heater is less than the maximum output of the boiler change the D...

Page 104: ...uns during central heat and frost protection call for heat Pump does not start for a DHW call for heat and will be forced off if there is a DHW call for heat and Domestic Hot Water Priority is active Primary Loop Pipe IWH Never Primary Loop Piped IWH Boiler Piped IWH Domestic Pump run pump for Activates the Domestic pump output according to selected function Never Pump is disabled and not shown on...

Page 105: ...r Selections System Pump Central Heat Optional Priority Boiler Pump any demand DHW Pump Primary Loop Piped IWH DHW Priority Enable is optional Explanation This piping arrangement permits the system pump to run or not run when there is a domestic hot water call for heat Domestic hot water priority is optional It is permissible for the domestic and system pumps to run at the same time The boiler pum...

Page 106: ...g Range Choices Parameter and Description 180 F 80 F to 190 F Domestic Hot Water Setpoint The Domestic Hot Water DHW Setpoint parameter is used to create a minimum boiler water temperature setpoint that is used when DHW heat demand is on When the DHW heat demand is not on the contact is open or not wired this setpoint is ignored 170 F 80 F to 190 F Domestic Hot Water Thermostat Sleep or Away Setba...

Page 107: ...ss calculation It is typically set to the coldest outdoor temperature 70 F 32 F to 100 F High Outdoor Temperature The High Outdoor Temperature parameter is the outdoor temperature at which the Low Boiler Water Temperature is supplied This parameter is typically set to the desired building temperature 110 F 70 F to 190 F Low Boiler Water Temperature The Low Boiler Water Temperature parameter is the...

Page 108: ...ype Central Heat Setpoint Heating Element Type 180 to 190 F Fan Coil 100 to 140 F In Slab Radiant High Mass Radiant 160 to 190 F Convection Baseboard Fin Tube Convective 130 to 160 F Staple up Radiant Low Mass Radiant 130 to 160 F Radiant Baseboard 140 to 160 F Radiators Figure 57 Outdoor Reset Curve ...

Page 109: ...mA input on Terminal 9 10 is ignored 4 20mA 4 20mA Input on Terminal 9 10 is used as the temperature setpoint The following two parameters may be used to adjust the signal range 130 F 80 F Central Heat Setpoint Central Heat 4 20mAdc Setup 4 mA Water Temperature Sets the Central Heat Temperature Setpoint corresponding to 4mA for signal input on terminal 9 10 Voltage below 4mA is considered invalid ...

Page 110: ...ome on and Limit Open will flash in the Active Faults screen on the display Push the reset button to restore normal operation If yellow light does not come on determine why the low water cutoff is not working properly 2 Follow the procedure for turning the boiler off per Figure 51 Lighting Instructions 3 Inspect the wiring to verify the conductors are in good condition and attached securely DANGER...

Page 111: ...ivalent system water treatment products may be used in lieu of products referenced above 2 System Freeze Protection a The following heating system freeze protection products are recommended for Alpine boilers i Fernox Protector Alphi 11 combined antifreeze and inhibitor Follow manufacturer application procedure to insure proper antifreeze concentration and inhibitor level Above referenced product ...

Page 112: ...s and disconnect overflow switch wire pigtails from boiler wiring c Using pliers release spring clip securing the overflow switch to condensate trap body and remove the switch Note that the switch has factory applied silicon adhesive seal which may have to be carefully cut all around to facilitate the switch removal d Insure the trap overflow switch port is not obstructed with silicon seal debris ...

Page 113: ...elease spring clip securing the overflow switch to condensate trap body and remove the switch Note that the switch has factory applied silicon adhesive seal which may have to be carefully cut all around to facilitate the switch removal f Using pliers release spring clip securing condensate trap body to the heat exchanger bottom drain stab g Firstly pull the trap downwards to release from the heat ...

Page 114: ...r heat and the temperature is greater than setpoint Boiler not responding to Domestic Hot Water Heat Request Boiler is not sensing Domestic Hot Water Heat Request Check wiring for loose connection miswiring or defective indirect water heater aquastat Boiler Running but System or Boiler Circulator is not running Check wiring for loose connection miswiring When there is a Domestic Hot Water Heat Req...

Page 115: ...nsor fault Shorted or open return temperature sensor Shorted or mis wired return sensor wiring Defective return sensor 8 Supply sensor fault Shorted or open supply temperature sensor Shorted or mis wired supply sensor wiring Defective supply sensor 9 DHW sensor fault Shorted or open Domestic Hot Water DHW temperature sensor Shorted or mis wired DHW sensor wiring Defective DHW sensor 10 Stack senso...

Page 116: ...ning at Light off rate when it should or fan speed signal not being detected by Sage2 1 Loose connection in 120 VAC fan wiring Loose or miswired fan speed harness Defective fan 19 Purge rate proving failed Blower is not running at Purge rate when it should or fan speed signal not being detected by Sage2 1 Loose connection in 120 VAC fan wiring Loose or miswired fan speed harness Defective fan 20 I...

Page 117: ...taining Plate 101735 01 16 Observation Glass 101736 01 17 Observation Glass Gasket 101737 01 31 Air Vent Valve 101586 01 32 Water Temp Sensor 2 101685 01 33 High Limit 101653 01 M6x1 Hex Flange Nut Not Shown 6 101724 01 Gas Air Intake Duct Assembly Not Shown 101725 01 101725 02 N A Gas Air Intake Duct Weldment Not Shown N A 102615 01 Burner Plate Not Shown 101727 01 Burner Plate Insulation Warning...

Page 118: ...ontrol 101585 01 101585 02 101585 03 101585 04 101585 05 101585 06 101585 07 Sage2 1 Control 102852 01 102852 02 102852 03 102852 04 102852 05 102852 06 102852 07 23 Gas Valve Flange Kit N A 102972 03 24 Blower 101527 01 101528 01 101529 01 101530 01 101531 01 25 Blower Inlet Shroud Assembly 101704 01 101704 02 101704 03 101704 04 101704 05 26 Blower Outlet Gasket 101345 01 102614 01 27 Blower Mou...

Page 119: ...Hose 7016039 7016046 37 Rubber Grommet Condensate Trap 101595 01 38 Condensate Trap Blow Molded 101239 01 39 Spring Clip Condensate Trap 2 101632 01 40 Blocked Condensate Drain Switch 101587 01 41 Condensate Comp Fitting 101546 01 104 Hex Flange Nut 10 32 101864 01 105 Barbed Fitting 1 8 101863 01 106 Silicone Tube Gray 7 101865 01 XV Repair Parts continued ...

Page 120: ...142 05 103142 06 103142 07 43B Control Panel Assembly Programmed 2000 or 7000 Includes all parts shown 103142 08 103142 09 103142 10 103142 11 N A 43C Control Panel Assembly Programmed 7001 10 000 includes all parts shown N A 103067 03 103067 04 103067 05 N A 44 Programmed Display with Mounting Hardware 102726 02 45 Jacket Upper Front Panel 102778 01 46 Sage2 1 Programmed 103141 01 103141 02 10314...

Page 121: ... Bracket 2 101593 01 1 101593 01 58 Jacket Top Panel 101218 01 101218 02 101218 03 101218 04 101218 05 101218 06 101218 07 59 Bracket Assembly Right Side 101232 01 101232 02 101232 03 101232 04 101232 05 101232 06 101232 07 60 Side Bracket 101224 01 101224 02 101224 03 101224 04 101224 05 101224 06 101224 07 61 Bracket High Voltage Terminal 102780 01 62 Bracket Rear HX Support 101381 01 63 Bracket...

Page 122: ...193 01 1 1 4 x 30 Schedule 40 CPVC Pipe 102193 02 1 84 3 Schedule 80 CPVC 90 Elbow 102192 01 1 1 4 Schedule 80 CPVC 90 Elbow 102192 02 1 85 8 oz Bottle of Transition Cement 102195 01 1 1 1 86 8 oz Bottle of Primer 102194 01 1 1 1 87 3 x 3 CPVC PVC Vent System Connector 102183 01 1 3 x 4 CPVC PVC Vent System Connector 102183 02 1 4 x 4 CPVC PVC Vent System Connector 102183 03 1 88 3 x 4 CPVC PVC Ve...

Page 123: ...ARTS CARTON 102942 01 102942 02 102942 03 73 Temperature Pressure Gauge 100282 01 74 External Gas Shut Off Valve 806SOL0005 101615 01 75 Relief Valve 81660363 81660302 77 Boiler Drain Valve 806603061 78 Boiler Stacking Brackets 2 101679 01 79 Boiler Stacking Bracket Screws 8 80860743 80 Outdoor Temperature Sensor Not Shown 1 102946 01 ...

Page 124: ...Collar Plate Assembly 102871 01 N A 116 Air Collar Plate Gasket 102876 01 N A 117 Access Panel Rear Air Box 102873 01 N A 118 Horizontal Strip Gasket 2 102875 01 N A 119 Vertical Strip Gasket 2 102874 01 N A 120 Access Panel Gasket 102877 01 N A 1 4 20 x 5 8 Hex Head Cap Screw Not Shown 4 80861312 N A 1 4 20 Hex Nut w Lock Not Shown 4 80860456 N A Sheet Metal Screw 8 x 1 2 Black Oxide Not Shown 18...

Page 125: ...2 Long sleeved loose fitting clothing 3 Gloves 4 Eye Protection Take steps to assure adequate ventilation Wash all exposed body areas gently with soap and water after contact Wash work clothes separately from other laundry and rinse washing machine after use to avoid contaminating other clothes Discard used RCF components by sealing in an airtight plastic bag RCF and crystalline silica are not cla...

Page 126: ...Connector Floor Mounted Boiler Builds Figure 6A 24 Near Boiler Vent Combustion Air Piping Floor Mounted Boiler Builds Figure 6B 25 Field Installation of CPVC Vent Pipe Wall Mounted Boiler Builds Figure 7 25 CPVC PVC Vent Pipe Thru Combustible Wall Installation Figure 8 26 Direct Vent Sidewall Figure 9 26 Rodent Screen Installation Figure 10 27 Direct Vent Optional Sidewall Snorkel Terminations Fig...

Page 127: ...ately Piped Indirect Water Heater Section IX Boiler Stacking Figure 38 62 Stacking Boiler Attachment Bracket Placement Section X Modular Installations Figure 39 64 Modular Boiler Direct Vent Termination Figure 40 65 Modular Boiler Concentric Vent Termination Figure 41A 67 Modular Boiler Water Piping w Domestic Hot Water Heater Figure 41B 68 Alternate Modular Boiler Water Piping w Domestic Hot Wate...

Page 128: ...re 53 90 Dungs Gas Valve Detail Section XII Operation Figure 54 96 Home Screen Figure 55 97 Status Screen Figure 56 99 Display Arrangement Overview Figure 57 108 Outdoor Reset Curve Section XIII Service and Maintenance Figure 58 111 Ignitor Electrode Gap Figure 59 112 Condensate Overflow Switch Orientation Appendix A Figures continued ...

Page 129: ...tainless Steel Table 8B 30 Alternate Vent Systems and Vent Components Stainless Steel Table 9 31 Concentric Vent Length Table 10 31 Concentric Vent Components Section VI Water Piping and Trim Table 11 43 Flow Range Requirement Through Boiler Table 2A 44 Recommended Circulator Models for Alpine ALP Boilers Based on 25 F Temperature Differential and Up to 75 ft Equivalent Length Near Boiler Piping S...

Page 130: ... Table 25 91 Recommended Combustion Settings LP Gas Section XII Operation Table 26 93 Order of Priority Table 27 95 Frost Protection Table 28 96 Boiler Status Table 29 97 Boiler Priority Definitions Table 29 103 Parameters Changed Using the Boiler Type Parameter Selections Table 30 103 Sage2 1 Control Spare Part Numbers Section XV Repair Parts N A Pages 117 thru 124 Appendix B Tables continued ...

Page 131: ...131 SERVICE RECORD DATE SERVICE PERFORMED ...

Page 132: ...er adjustment control settings care or maintenance d This warranty cannot be considered as a guarantee of workmanship of an installer connected with the installation of the U S Boiler Company Inc boiler or as imposing on U S Boiler Company Inc liability of any nature for unsatisfactory performance as a result of faulty workmanship in the installation which liability is expressly disclaimed e Boile...

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Burnham Alpine ALP080, Installation, Operating And Service Instructions

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