IN S TAL L AT ION , OP E R AT IN G AN D S E R V IC E IN S T R U C T ION S F OR AL P I N E ™ C ON D E N S IN G H IGH E F F IC IE N C Y D IR E C T V E N T GA S - F I R E D H OT WAT E R BOI L E R 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).
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.
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.
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......................................
Figure 1A: Alpine™ - Models ALP080 thru ALP210
Figure 1B: Alpine™ - Models ALP285 thru ALP399
Table 2A: Rating Data - Models ALP080 thru ALP399 (0 to 2000 Feet Elevation Above Sea Level) Alpine Series Gas-Fired Boilers * Model Number ALP080 Input (MBH) Min. Max. 16 80 ** Output (MBH) 73 Net I=B=R Thermal AFUE Ratings Efficiency % Water (MBH) (%) 63 Combustion Efficiency (%) Boiler Water Heat Transfer Area Volume (Gal.) (Sq. Ft.) 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.
II. Pre-Installation 2. Access is provided to the condensate trap located underneath the heat exchanger. WARNING If you do not follow these instructions exactly, a fire or explosion may result causing property damage or personal injury. DANGER Do not install boiler where gasoline or other flammable vapors or liquids, or sources of hydrocarbons (i.e. bleaches, cleaners, chemicals, sprays, paint removers, fabric softeners, etc.) are used or stored. D. Install on level floor.
Figure 2: Clearances To Combustible and Non-combustible Material III. Unpacking Boiler CAUTION D. Remove boiler from cardboard positioning sleeve on shipping skid. Do not drop boiler. WARNING A. Move boiler to approximate installed position. B. Remove all crate fasteners. C. Lift and remove outside container. 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.
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.
2. The Alpine™ is designed to be installed as a Direct Vent boiler. The air for combustion is supplied directly to the burner enclosure from outdoors and flue gases are vented directly outdoors (through wall or roof). 1. Horizontal vent pipe must maintain a minimum ¼ inch per foot slope down towards boiler. 3. The following combustion air/vent system options are approved for use with the Alpine™ boilers: i.
Table 4: Vent System Components Included with Boiler Quantity Part Number Vent System Components ALP080 & ALP105 (P/N 102189-01) ALP150 & ALP210 (P/N 102189-02) ALP285 & ALP399 (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 --
Table 7: Vent/Combustion Air Pipe Length Boiler Model 3” Combustion Air Pipe (Equivalent Length) 4” Combustion Air Pipe (Equivalent Length) 3” Vent Pipe (Equivalent Length) 4” Vent Pipe (Equivalent Length) 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.
Figure 3: Expansion Loop and Offset 6. Remove the Silicone flue 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 flue sensor and insert the flue temperature sensor into the flue sensor plug until it is firmly engaged. See Figure 4. 7.
Figure 4: 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.
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. 2.
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.
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 lengths. 3.
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° elbow so that elbow leg is opposite the building’s exterior surface. 4. Position the Collar onto jacket combination rear/ bottom panel and insert collar inner stainless steel vent pipe into the heat exchanger vent outlet. 7.
Figure 12: Field Installation of Boiler Concentric Vent Collar codes. Contact local building or fire officials about restrictions and installation inspection in your area. 5. Provide and maintain vent pipe minimum clearances 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.
Table 11: Concentric Vent Length Boiler Model Vent Length Concentric Vent Inner/Outer Pipe Dia., mm Minimum Factory Supplied Horizontal (Wall) Terminal 80/125 mm 21-7/8 in Factory Supplied Horizontal (Wall) Terminal 100/150 mm 32 in * Maximum Wall Opening Diameter ALP080 ALP105 ALP150 ALP210 ALP285 ALP399 Total of 60 Equivalent ft. 5-1/2 in 6-1/2 in Note: * With optional concentric vent components. See Table 10 for details. The direct vent termination location is restricted as follows: a.
several marks around the outer pipe to establish a cut line. See Figure 15 ‘ Cutting Outer Pipe’. d. Carefully cut the outer pipe at the marked line using aviation shears, a hacksaw etc. Ensure the pipe is cut square and cut end is deburred. Figure 15: Cutting Outer Pipe Figure 13: Horizontal (Wall) Terminal Installation b. Measure dimension “L” from exterior wall outer surface to the end of the last fitting (or end of installed Boiler Concentric Vent Collar). See Figure 14 ‘Dimension “L”’. e.
WARNING The terminal vent portion is offset towards the top inside the outer pipe of the Horizontal Concentric Vent Terminal to provide vent pipe pitch towards the boiler for condensate removal. See Figure 17 ‘Horizontal (Wall) Terminal Detail’. It is imperative to properly mount the vent terminal. The terminal orientation label is located on the inside of the terminal Outside Wall Plate. Insure the vent terminal is positioned as shown in Figure 18 before securing the Outside Wall Plate to exterior wall.
Figure 19: Vertical Concentric Vent Installation outer pipes to start the screw. Use a drill stop or other means to ensure that the drill bit does not penetrate more than 3/8” into the outer pipe. Do not use sheet metal screws longer than ½”. When Additional Concentric Vent Piping is needed 1. If additional concentric vent piping is needed: a. Concentric Vent Cut-To-Length Extension pipes, identified in Tables 8 and 10 CAN BE CUT to required length when used as an extension.
Figure 22: Cutting Straight Pipe b. 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 2d above) is covered. On other fittings, the bead on the male pipe will be bottom out on the collar (see Figure 24). c. The male end of cuttable fittings must be held to the collar with three (3) #10 x 1/2” sheet metal screws.
a. Determine the centerline of the terminal location on the roof. For flat 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. For sloped roof, cut a hole in the roof large enough for the terminal to pass through the roof while remaining plumb. CAUTION If the boiler is located directly under the hole, cover it while cutting the hole to prevent debris from falling onto boiler. b.
Table 10: Cut-To-Length Extensions (Cuttable) Part No. Component Description 101163-01 Cut-To-Length Extension, 500 mm (19-1/2”) 101162-01 Cut-To-Length Extension, 1000 mm (39”) 101550-01 Cut-To-Length Extension, 500 mm (19-1/2”) 101551-01 Cut-To-Length Extension, 1000 mm (39”) Size 80/125 mm 100/150 mm Chimney Chase Installation. A vertical concentric vent system, either 80/125 mm or 100/150 mm can be installed in an UNUSED masonry chimney. Refer to Figure 28. a.
Figure 28: Chimney Chase Installation 28
V. Condensate Disposal A. Condensate Trap 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 flue gases in the boiler. The trap has factory installed overflow switch, which shuts down the boiler in the event the drain line becomes obstructed, preventing proper condensate removal.
Figure 29: Condensate Trap and Drain Line
VI. Water Piping and Trim WARNING Failure to properly pipe boiler may result in improper operation and damage to boiler or structure. Install boiler so that the gas ignition system components are protected from water (dripping, spraying, rain, etc.) during appliance operation and service (circulator replacement, etc.). NOTICE Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components, and can lead to boiler failure.
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 Valve, ¾” NPT Drain Valve. b. Install close nipple into tee branch, then, screw the assembly into boiler left side front ¾” tapping making sure tee run outlets are in vertical plane and parallel to boiler side. c. Mount ¾” MPT x ¾” FPT Pressure Relief Valve into the tee top outlet. d. Install Drain Valve into the tee bottom outlet. 2. ALP399 Boiler Model a.
B. Piping System To Be Employed. NOTICE 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 flow through the boiler remain within the limits shown in Table 11, any time the boiler is firing. Failure to maintain the flow through boiler within specified limits could result in erratic operation or premature boiler failure. 1.
a. The flow rate through the isolated near-boiler loop is maintained by factory recommended and installer supplied boiler circulator. b. The flow rate through the isolated near-boiler loop is completely independent of the flow rate through the heating system loop(s). c. The flow rate through the heating system loop(s) is controlled by installer sized/provided system loop circulator(s). d.
1 1 1 Boiler Model ALP080 ALP105 ALP150 1 1 1 Boiler Return Connection, Inch, FPT 1 1 1 NearBoiler Piping Supply Pipe Size, Inch 1 1 1 NearBoiler Piping Return Pipe Size, Inch 13.8 9.6 7.3 Max Allowable Flow thru Boiler, GPM @ 20°F Delta T 11 7.7 5.8 Flow, GPM @ 25°F Delta T 7.9 5.5 4.2 Min Req’d Flow thru Boiler, GPM @ 35°F Delta T 14 SL119 6 SL50 6 6 SL35 SL70 6 SL27 17 10 9.5 9 9 17 10 6 14 SL70 SL119 9.
1 1-1/4 1-1/2 Boiler Model ALP210 ALP285 ALP399 1-1/2 1-1/4 1 Boiler Return Connection, Inch, FPT 2 1-1/2 1-1/4 NearBoiler Piping Supply Pipe Size, Inch 2 1-1/2 1-1/4 NearBoiler Piping Return Pipe Size, Inch 37.7 26.5 19.4 Max Allowable Flow thru Boiler, GPM @ 20°F Delta T 30.2 21.2 15.5 Flow, GPM @ 25°F Delta T 21.5 15.1 11.
Table 13: Fitting and Valve Equivalent Length (cont’d) Table 13: Fitting and Valve Equivalent Length Copper Fitting and Sweat Valve Equivalent Length (Ft) Threaded Fitting and Valve Equivalent Length (Ft) Black Threaded Pipe or Valve Size Fitting or Valve Description Copper Pipe or Valve Size 1 1¼ 1½ Fitting or Valve Description 1 1¼ 1½ 90° Elbow 2.5 3.0 4.0 90° Elbow 2.6 3.5 4.0 Long Radius Elbow (45° or 90°) 1.4 1.8 2.2 Tee (thru flow) 1.8 2.3 2.7 Tee (Branch flow) 5.3 6.9 8.
Figure 31A: Near Boiler Piping - Heating Only (with Central Heating Circulators)
Figure 31B: Near Boiler Piping - Heating Only (with Central Heating Zone Valves)
Figure 32A: Near Boiler Piping - Heating Plus Indirect Water Heater (with Central Heating Circulators)
Figure 32B: Near Boiler Piping - Heating Plus Indirect Water Heater (with Central Heating Zone Valves)
Figure 32C: Near Boiler Piping - Heating (with Central Heating Circulators) Plus Alternately Piped Indirect Water Heater
Figure 32D: Near Boiler Piping - Heating (with Central Heating Zone Valves) Plus Alternately Piped Indirect Water Heater
NOTICE Where it is not possible to install a separate boiler loop, the system circulator must be sized to ensure that the flow through boiler stays within the defined parameters to prevent overheating when the boiler is fired at it’s full rated input. Install a flow meter to measure the flow, or fire the boiler at full rate and ensure the boiler DT does not exceed 35°F. 2. Direct connection of Alpine (ALP) boiler to heating system, similar to a conventional boiler, is NOT RECOMMENDED because: a.
D. Special Situation Piping Installation Requirements Observe the following guidelines when making the actual installation of the boiler piping for special situations: 1. Systems containing high level of dissolved oxygen – Many hydronic systems contain enough dissolved oxygen to cause severe corrosion damage to Alpine (ALP) boiler heat exchanger.
VII. Gas Piping 3. Length of piping and number of fittings. Refer to Tables 14A (natural gas) or 14B (LP gas) for maximum capacity of Schedule 40 pipe. Table 15 lists equivalent pipe length for standard fittings. WARNING 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.
Table 14B: Maximum Capacity of Schedule 40 Black Pipe in CFH* (LP Gas) For Gas Pressures of 0.5 psig or Less Inlet Pressure 11.0 Inch W.C.; 0.3 Inch W.C. Pressure Drop Length of Pipe, Ft. Nominal Pipe Size, In. Inside Diameter, In. 10 20 30 40 50 60 70 80 90 100 ½ 0.622 88 60 48 41 37 33 31 29 27 25 ¾ 0.824 184 126 101 87 77 70 64 60 56 53 1 1.049 346 238 191 163 145 131 121 112 105 100 1¼ 1.380 710 488 392 336 297 269 248 231 216 204 1½ 1.
Table 16: Specific Gravity Correction Factors Specific Gravity Correction Factor Specific Gravity Correction Factor 0.60 1.00 0.90 0.82 0.65 0.96 1.00 0.78 0.70 0.93 1.10 0.74 0.75 0.90 1.20 0.71 0.80 0.87 1.30 0.68 0.85 0.81 1.40 0.66 C. Pressure test. See Table 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.
VIII. Electrical 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 more than one source. Make sure all power is off before attempting any electrical work.
• Black – Line voltage “hot” • White – “Neutral” for boiler and circulators • Red – “Heating” circulator “hot” • Blue – “Indirect Water Heater “ circulator “hot” • Green – Ground connection 2. Maximum circulator continuous current draw is 2A. With primary/secondary piping, it may be desirable to use the boiler to directly control the primary circulator in addition to the secondary circulator.
Figure 35: Wiring Connections Diagram 51
Figure 36: Ladder Diagram 52
Figure 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 53
Figure 37B: Modified Wiring For DHW Priority When Using Low Flow Circulator Piped Off System Header Heating (with Central Heating Zone Valves) Plus Alternately Piped Indirect Water Heater 54
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 Time Delay Relay Box (P/N 101693-01) installation is strongly recommended. See Figure 38 “Wiring for MCBA Modulating Boiler Control Time Delay Relay Box” and follow the following installation steps: a. Turn off power to boiler. b.
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 benefits of greater operational efficiency, floor space savings and boiler redundancy, the Alpine (ALP) boilers may be installed stacked one on the top of the other. Refer to Table 18 “Alpine (ALP) Boiler Model Stacking Combinations” for details.
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 “Venting” of the manual for specifics of individual boiler vent termination. Follow instructions in Section V for each individual boiler flue gas condensate line construction and condensate disposal.
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. 1. Each individual module (boiler) must have own combustion air intake pipe and combustion air intake terminal. Refer to Section IV “Venting” of these Instructions for individual module (boiler) combustion air intake guidelines and options. 2.
Figure 40: Modular Boiler Direct Vent Termination
Figure 41: Modular Boiler Concentric Vent Termination
If vertical vent terminals cannot end in one plane, they must be spaced no closer than three (3) feet horizontally. D. Modular Boiler Gas Piping 1. Individual module (boiler) gas pipe sizing specific details 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.
Figure 42: Modular Boiler Water Piping w/Domestic Hot Water Heater Installing a low water cutoff in the system piping of modular boilers is strongly recommended and may be required by Local Codes.
Figure 43: Modular Boiler Water Piping w/Domestic Hot Water Heater (Continued)
The Tekmar 265 Control (or equal) can control either 3 modulating boilers or 2 modulating boilers and an Indirect Water Heater. When a call for heat is received by the Tekmar 265 Control, the control will fire either one or more boilers in either parallel or sequential firing mode to establish a required reset water temperature in the system supply main based on outdoor temperature.
The Tekmar 264 Control (or equal) can control up to four (4) boilers and an Indirect Water Heater by utilizing stage firing. When a call for heat is received by the Tekmar 264 Control, the control will fire either one or more boilers in sequential firing mode to establish a required reset water temperature in the system supply main based on outdoor temperature.
XI. System Start-up A. Verify that the venting, water piping, gas piping and NOTICE electrical system are installed properly. Refer to installation instructions contained in this manual. 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 trapped in the boiler. To perform a long term pressure test including the boiler, ALL trapped air must first be removed from the boiler.
Alpine™ Series Lighting and Operating Instructions Figure 46: Lighting Instructions 67
Figure 47: Burner Flame H. Purge Air From Gas Train K. Perform Combustion Test Upon initial start-up, the gas train will be filled with air. Even if the gas line has been completely purged of air, it may take several tries for ignition before a flame is established. If more than 5 tries for ignition are needed, it will be necessary to press the reset button to restart the boiler.
N. Adjust Supply Water Temperature As shipped, the heating and indirect water heater set point supply temperatures are both set to 180°F. If necessary, adjust these to the appropriate settings for the type of system to which this boiler is connected. See Section XII “Operation” of this manual for information on how to do this. O. Adjust Thermostats Adjust the heating and indirect water heater thermostats to their final set points. P.
7. Perform a combustion test. Boilers equipped with a concentric vent system have a flue gas sample tap located in the boiler vent collar (under the screw cap). 8.
WARNING The throttle adjustments shown in Table 22 are approximate. The final throttle setting must be found using a combustion analyzer. Leaving the boiler in operation with a CO level in excess of the value shown in Table 23 could result in injury or death from carbon monoxide poisoning. NOTICE If the throttle is very far out of adjustment on the “rich” (counter-clockwise) side, the boiler burner may be running at 0% Excess Air or even with air deficiency.
XII. Operation I. Factory Preset Boiler Operating Parameters (See Table 25 for Parameter Descriptions) A. The Alpine (ALP) boiler uses a microprocessor based Honeywell control, known as a “MCBA”, to manage all boiler functions including flame supervision and modulation. Two set point or “target” boiler supply temperatures are stored in the MCBA’s memory; one for space heating and one for domestic water production.
Table 25: Parameter Descriptions Access Parameter Code No.
Figure 50: Basic Menu Tree
D. Two 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. A list of these codes, and their meanings, is shown in Table 29 in Section XIV Troubleshooting. The boiler will automatically restart once the condition that caused the lockout is corrected. 2.
Additionally, either the keypad or the personal computer can be used to obtain information about the boiler current status and operating history. A. Adjusting Parameters via Boiler Keypad Entering the Access Code 1. With boiler running, toggle the Mode key until you reach the (STBY) Standby mode. 2. Depress and hold the Step key and then quickly depress and hold the Mode key for 2 - 6 seconds until the display reads (CODE). Release the Mode key, then the Step key.
Figure 52: Expanded Menu Tree (Cont’d on next page) 77
Figure 52: Expanded Menu Tree (cont’d.
14; Parameter 13 defines the “thousands” and hundreds” places and Parameter 14 defines the “tens” and “ones” places. The ignition fan speed is only adjustable in increments of hundreds, so only one parameter (19) is required to define it. IMPORTANT: Field adjustment of fan speeds is not recommended. b. In some cases one two-digit number defines two separate parameters.
B. Adjusting Parameters via Personal Computer with GCI Interface 1. Operating System Requirements The GCI Interface requires a PC computer running a Windows 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. Connect the serial cable from the GCI to the computer. b. Plug in the GCI. c. Open the lower front jacket panel.
Figure 55: Gascom Menu Tree 4. Double-click on the desired parameter. A window will open with either a field or a pull down list of options will appear. Enter or select the desired value for the parameter. From the Monitor Menu select “Monitor MCBA”. This will bring up a window which plots the following information: 5. Click OK. 1. Temperatures: 6. Repeat Steps (3) - (5) to change any other desired parameters.
Hotwater - Indirect water heater thermostat (“1” = Calling, “0” = Not Calling) Pump - Heating circulator (“1” = On, “0” = Off) Air-switch - Status of air pressure switch (“1” = Closed, “0” = Open) Gaspressure - This is actually the status of the high limit (“1” = Closed, “0” = Open) GasValve - Status of gas valve (“1” = Open , “0” = Closed) Flame - Shows whether the MCBA detects the presence of the burner flame (“1” = Flame, “0” = No Flame) 3.
Table 27: NTC Sensor Resistance Values 83
XIII. Service and Maintenance DANGER This boiler uses flammable gas, high voltage electricity, moving parts, and very hot water under high pressure. Assure that all gas and electric power supplies are off and that the water temperature is cool before attempting any disassembly or service. Do not attempt any service work if gas is present in the air in the vicinity of the boiler. Never modify, remove or tamper with any control device.
3. Inspect the wiring to verify the conductors are in good condition and attached securely. 10. Reinstall the burner, burner hood and fan/gas valve assembly. 11. Reconnect any wiring which has been disconnected. CAUTION Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing. 4. Remove the ignition electrode and inspect it for oxides. Clean the oxides from the electrode with steel wool.
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. Insure that system fluid contains proper glycol concentration and inhibitor level. The system should be tested at least once a year and as recommended by the manufacturer of the glycol solution.
Figure 57: Condensate Overflow Switch Orientation
XIV: Troubleshooting WARNING Turn off power to boiler before replacing fuses or working on wiring. A. Troubleshooting problems where no error code is displayed. Refer to Table 28 for problems and possible causes. Table 28: No Error Code Displayed CONDITION POSSIBLE CAUSES Display Blank, Fan off, LWCO lights off • No 120VAC Power at boiler.
B. Trouble shooting problems where 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. Table 29: Soft Lockout Codes Displayed CODE CONDITION POSSIBLE CAUSES b 08 Pressure switch circuit open • Blockage in intake or vent system.
C. Trouble shooting problems where a hard lockout code is displayed. When a hard lockout occurs, the boiler will shut down and the display will flash the letter “E” followed by a two digit service code. Once the condition that caused the lockout is corrected, the boiler will need to be manually reset using the RESET button on the display. Table 30: Hard Lockout Codes Displayed CODE CONDITION POSSIBLE CAUSES A flame signal was present when there should be no flame.
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, or have questions regarding the availability of Burnham products or repair parts, please contact Burnham Customer Service at (717) 481-8400 or Fax (717) 481-8408.
Key No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 31 32 33 42 92 Description Heat Exchanger, Burner, Etc.
Key No.
Key No. 35 36 37 38 39 40 41 94 Description Air Pressure Switch Air Pressure Switch Hose Rubber Grommet, Condensate Trap Condensate Trap, Blow Molded Spring Clip, Condensate Trap Blocked Condensate Drain Switch Condensate Comp.
Key No.
Key No.
Key No.
Key No.
important Product Safety information Refractory Ceramic Fiber Product Warning: The Repair Parts list designates parts that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to temperatures about 1805°F, such as during direct flame contact, RCF changes into crystalline silica, a known carcinogen. When disturbed as a result of servicing or repair, these substances become airborne and, if inhaled, may be hazardous to your health.
Limited Warranty FOR RESIDENTIAL GRADE STAINLESS STEEL WATER BOILERS Subject to the terms and conditions set forth below, U.S. Boiler Company, Inc. Lancaster, Pennsylvania hereby extends the following limited warranties to the original owner of a residential grade stainless steel water boiler manufactured and shipped on or after november 1, 2007: ONE YEAR LIMITED WARRANTY ON RESIDENTIAL STAINLESS STEEL GRADE WATER BOILERS U.S. Boiler Company, Inc.
