Burnham Alpine Series Installation, Operation And Service Instructions

Text of Burnham Alpine Series User Guide:

• Burnham Alpine Series, 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)

• Burnham Alpine Series, 114 XIV. Troubleshooting Condition Possible Cause Display Blank, Fan off, LWCO lights off, no green power light on Sage2.1 Controller No 120VAC Power at boiler. Check breaker and wiring between breaker panel and boiler. Display Panel Blank, Fan running • Loose 120V AC connection wiring between boiler J-Box and transformer • Loose 24 Vac connection wiring between transformer and Sage2.1 • Loose 5 Vdc connection wiring between display and Sage2.1 Boiler res, but display panel is blank • Loose 5 Vdc connection wiring between display and Sage2.1 • Defective display Boiler not responding to call for heat, Status screen reads “Central Heat T-Stat Off” Boile

• Burnham Alpine Series, 89 Figure 52: Burner Flame L. Test External Limits Test any external limits or other controls in accordance with the manufacturer’s instructions. M. Check Thermostat Operation Verify that the boiler starts and stops in response to calls for heat from the heating thermostat and indirect water heater thermostat. Make sure that the appropriate circulators also start and stop in response to the thermostats. 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

• Burnham Alpine Series, 93 7. Priority Demand The Sage2.1 accepts a call for heat (demand) from multiple places and responds to each demand according to it’s relative importance. When more than one demand is present at one time the more important demand is selected as the “priority” demand and is used to operate the boiler and pumps. The selected priority demand is displayed on the boiler “Status” screen (see Figure 55). For example, when Domestic Hot Water (DHW) demand has priority the ring rate setpoint is set equal to the DHW Setpoint, the DHW, Boiler and System pumps respond to a DHW demand.

• 5 TABLE OF CONTENTS I. Product Description, Specications and Dimensional Data...................... 6 II. Pre-Installation & Boiler Mounting ............................................................ 13 III. Unpacking Boiler........................................................................................ 17 IV. Venting...........................................

• Burnham Alpine Series, 72 Table 21 (continued): Recommended Circulator Models for Alpine (ALP) Boilers and Alliance SL Indirect Water Heaters Installed as Part of Near-Boiler Piping Up to 75 Ft. Equivalent Length - Domestic Hot Water Circulator Boiler Model Boiler Supply Connection, Inch, FPT Boiler Return Connection, Inch, FPT Near- Boiler Piping Supply Pipe Size, Inch Near- Boiler Piping Return Pipe Size, Inch Max Allowable Flow thru Boiler, GPM @ 20°F Delta T Flow, GPM @ 25°F Delta T Min Req’d Flow thru Boiler, GPM @ 35°F Delta T Alliance SL Models to be

• Burnham Alpine Series, 41 A. Installation of Factory Supplied Piping and Trim Components Alpine (ALP) boilers have factory supplied Miscellaneous Part Carton (P/N 102942-01 – ALP080 thru ALP210; 102942-02 – ALP285; 102942-03 – ALP399 thru ALP500), which includes supply piping components, gas piping components, Temperature & Pressure Gauge, Pressure Relief Valve and Drain Valve. See Figure 30 “ Factory Supplied Piping and Trim Installation”. Install these components prior to connecting boiler to system piping as follows: VI. Water Piping and Trim Figure 30: Factory Supplied Piping and Trim Installation WARNING Failure to p

• Burnham Alpine Series, 101 Value to be edited (blinks while editing) Increase & Decrease Value buttons Cancel Edit Accept Edit Note: the value modified with the increase and decrease buttons is not accepted unless this button is also pressed CH Setpoint Central Heat < > 180 F i XII. Operation (continued) 4. Entering Adjust Mode The “Adjust mode” screen is accessed from the “Home” screen. The “Adjust Mode” provides contractors access to view and adjust additional information. a. Entering Adjustment Mode The Sage2.1 is factory programmed to

• 43 Boiler Model Boiler Supply Connection, Inch, FPT Boiler Return Connection, Inch, FPT Minimum Required Flow (GPM) @ 35°F DT Boiler Head Loss, Ft. @ 35°F DT Required Flow, (GPM) @ 30°F DT Boiler Head Loss, Ft. @ 30°F DT Required Flow, (GPM) @ 25°F DT Boiler Head Loss, Ft. @ 25°F DT Maximum Required Flow (GPM) @ 20°F DT Boiler Head Los

• 100 D. User Interface (continued) 3. Help Screens XII. Operation (continued) The “Help” screen provides access to active faults, lockout history, the service contact and the boiler reset button. The “Help” screen is accessed from the “Home” screen. Limit String Status Display This display is provided to identify the cause of an Interlock input “open�

• Burnham Alpine Series, 67 Figure 41A: Modular Boiler Water Piping w/Domestic Hot Water Heater (Page 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.

• Burnham Alpine Series, 17 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 2D: Bottom Mounting Bracket Installation / Boiler Wall Mounting Figure 2E: Access Panel and Gasket Installation II. Pre-Installation & Boiler Mounting (continued)

• Burnham Alpine Series, 62 permissible, providing common pipe has sufcient ow capacity to handle combined condensate volume of stackable combination. 2. Gas Piping - Follow instructions in Section VII “Gas Piping” of the manual for sizing and installation of an individual boiler. When common gas piping is sized, insure it will have adequate capacity for combined input (GPH gas ow) of the selected stackable boiler combination. Figure 38: Stacking Boiler Attachment Bracket Placement 3. Water Piping and Trim - Follow instructions in Section VI “Water Piping and

• Burnham Alpine Series, 19 Boiler Build Approved Direct Vent System Vent Material Orientation Termination Description Figures Component Table Part Floor Standing or Wall Hung Two-Pipe, CPVC/PVC Vent and PVC air intake (Factory Standard) CPVC/PVC Horizontal Standard (thru sidewall) The system includes separate CPVC vent pipe and PVC air intake pipe terminating thru sidewall with individual penetrations for the vent and air intake piping and separate terminals (tees). 4 thru 9 4A B. Optional Snorkel (thru sidewall) Same as above but separate snorkel type terminals. 4, 5A, 5B, 6, 7, 9, 10 4B Optional Vertical Vertical (thru roof) The system inclu

• Burnham Alpine Series, 74 Tekmar 265 Based Control System (or equal) Sequence of Operation The Tekmar 265 Control (or equal) can control up to three (3) boilers and an Indirect Water Heater. When a call for heat is received by the Tekmar 265 Control, the control will re either one or more boilers in either parallel or sequential ring mode to establish a required reset water temperature in the system supply main based on outdoor temperature. The boilers will modulate based on an Analog communication signal established between the Tekmar 265 Control an

• Burnham Alpine Series, 45 Table 13: Fitting and Valve Equivalent Length Copper Fitting and Sweat Valve Equivalent Length (Ft) Fitting or Valve Description Copper Pipe or Valve Size 1 1¼ 1½ 2 90° Elbow 2.5 3.0 4.0 5.5 45° Elbow 1.0 1.2 1.5 2.0 Tee (thru ow) 0.5 0.6 0.8 1.0 Tee (Branch ow) 4.5 5.5 7.0 9.0 Diverter Tee (typical) 23.5 25.0 23.0 23.0 Gate Valve 0.3 0.4 0.5 0.7 Globe Valve 25.0 36.0 46.0 56.0 Angle Valve 5.3 7.8 9.4 12.5 Ball Valve (standard port) 4.3 7.0 6.6 14.0 Ball Valve (full port) 1.9 1.4 2.2 1.3 Swing Check Valve 4.5 5.5 6.5 9.0 Flow-Check Valve (typical) 54.0 74.0 57.0 177.0 Buttery Valve 2.7 2.

• Burnham Alpine Series, 44 Table 12: Recommended Circulator Models for Alpine (ALP) Boilers Based on 25°F Temperature Differential and Up to 75 ft. Equivalent Length Near-Boiler Piping - Space Heating Circulator Boiler Model Boiler Supply Connection, Inch, FPT Boiler Return Connection, Inch, FPT Near-Boiler Piping Supply Pipe Size, Inch Near-Boiler Piping Return Pipe Size, Inch Flow, GPM @ 25°F Temp. Differential Combined Boiler & Piping Loop Head Loss, Ft. * Recommended Circulator Make & Model ALP080 1 1 1 1 5.8 10.3 Taco 0010 Grundfos UPS 15-58 FRC ALP105 1 1 1 1 7.7 15.1 Taco 0014 Grundfos UPS 26-99 FC (second speed) ALP150 1 1 1

• Burnham Alpine Series, 86 A. Verify that the venting, water piping, gas piping and electrical system are installed properly. Refer to installation instructions contained in this manual. B. Conrm all electrical, water and gas supplies are turned off at the source and that vent is clear of obstructions. C. Conrm that all manual shut-off gas valves between the boiler and gas source are closed. WARNING Completely read, understand and follow all instructions in this manual before attempting start up. D. If not already done, ush the system to remove sediment, ux and traces of boiler additives. This

• Burnham Alpine Series, 127 Appendix A - Figures (continued) Figure Number Page Number Description SectionV - Condensate Disposal Figure 29 40 Condensate Trap and Drain Line Section V - Water Piping and Trim Figure 30 41 Factory Supplied Piping & Trim Installation Figure 31 46 Near Boiler Piping - Heating Only (with Central Heating Circulators) Figure 32 47 Near Boiler Piping - Heating Plus Indirect Water Heater Figure 33 49 Isolation of the Boiler From Oxygenated Water with A Plate Heat Exchanger Section VII - Gas Piping Figure 34A 52

• Burnham Alpine Series, 36 IV. Venting (continued) Figure 24: Vertical Concentric Vent Installation Figure 23: Completing Horizontal (Wall Terminal Installation) • Install the roof ashing using standard practice on the roong system of the structure. • If not already done, assemble the venting system inside the building. The last section of pipe needs to be on the same center line as the terminal and within 19-1/4” of the top edge of the roof ashing. • Measure distance “H” from the top edge of the storm collar to the end of the last tting as shown in Figure 25. • Add 1” to distance “H”. Carefully mark this length on the pipe as shown in Figur

• Burnham Alpine Series, 25 4. Near-Boiler Vent/Combustion Air Piping - Floor Mounted Boiler Builds Refer to Figure 6A and the following Steps: a. All CPVC vent components supplied with boiler inside vent carton (3” or 4” Schedule 40 x 30” long CPVC pipe and 3” or 4” Schedule 80 CPVC 90° Elbow) must be used for near-boiler piping before transitioning to Schedule 40 PVC (ASTM 2665) pipe components for reminder of vent system. The CPVC 30” long straight pipe may be cut to accommodate desired vent conguration provided both pieces are used in conjunction with CPVC 90° Elbow before any PVC components are used. Ensure that the CPVC 90° Elbow is the rst

• Burnham Alpine Series, 106 XII. Operation (continued) “Press” Central Heat button to access the following parameters: Factory Setting Range / Choices Parameter and Description 180°F 80°F to 190°F Central Heat Setpoint Target temperature for the central heat priority. Value also used by the outdoor air reset function. 170°F 80°F to 190°F Central Heat Thermostat “Sleep” or “Away” Setback Setpoint Thermostat setback setpoint is used when the EnviraCOM thermostat is in “leave” or “sleep” modes and sensed at E-COM terminals D, R, and C. When setback is “on” the thermostat setback setpoint shifts the reset curve to save energy while home is in a reduc

• Burnham Alpine Series, 90 4. Before attempting to start the boiler, make the number of turns to the throttle screw called for in Table 24. 5. Attempt to start the boiler using the lighting instructions located inside the lower front cover of the boiler. If the boiler does not light on the rst try for ignition, allow to boiler to make at least four more attempts to light. If boiler still does not light, turn the throttle counter clockwise in 1/4 turn increments, allowing the boiler to make at least three tr

• Burnham Alpine Series, 66 e. Individual module (boiler) sidewall concentric vent terminals must be placed at least twelve (12) inches above the ground plus the expected snow accumulation. f. For vertical through the roof venting any adjacent individual module (boiler) vertical vent terminals, if level with each other, must be spaced no closer than 12 inches horizontally. If vertical vent terminals cannot end in one plane, they must be spaced no closer than three (3) feet horizontally. g. Chimney chase concentric venting is permitted for modules, when stackable, providing concentric vertical (roof) vent terminals, if level w

• 32 Figure 14: Field Installation of Boiler Concentric Vent Collar IV. Venting (continued) Figure 15: Cut-To-Length Extension (Cuttable) Figure 16: Fixed Extension (Non-Cuttable) 2. Field Installation of Boiler Concentric Vent Collar a. Locate and remove six mounting screws from the Miscellaneous Parts Carton. b. Position the Collar onto jacket combination rear/bottom panel a

• 98 XII. Operation (continued) No. Title Terminal Description 1 Check Wiring 1 & 2 Is the heating thermostat connected? Insure this is “dry”, non-powered input. 2 & 3 Is an IWH providing a boiler heat demand? 5 & 6 Is an Outdoor Air sensor used? If yes, refer to step 2 and 9 to activate outdoor air reset. 7 & 8 Is a header sensor used? If yes, r

• Burnham Alpine Series, 20 to prevent nuisance boiler shutdowns. However, boiler may be installed with vertical venting and sidewall combustion air inlet or visa versa, if installation conditions do not allow alternate arrangement. • The bottom of the vent and air intake terminal must be at least 12" (18" in Canada) above the normal snow line. In no case should they be less than 12" above grade level. • The bottom of the vent terminal must be at least 7 feet above a public walkway. • Do not install the vent terminal

More Instructions:

	Burnham Alpine Series Information sheet 05-03-2023 2	DOWNLOAD
	Burnham Alpine Series Supplemental instructions 01-01-2023 3	DOWNLOAD

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