Burnham 101603-01R2-12/09 Boiler User Manual

AL P I N E ™
WARNING: If the information in this
manual is not followed exactly, a fire or
explosion may result causing property
damage, personal injury or loss of life.
- Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
AVERTISSEMENT. Assurez-vous de bien
suivre les instructions données dans cette
notice pour réduire au minimum le risque
d'incendie ou d'explosion ou pour éviter
tout dommage matériel, toute blessure ou
la mort.
- Ne pas entreposer ni utiliser d'essence ni
d'autres vapeurs ou liquides inflam-mables
dans le voisinage de cet appareil ou de tout
autre appareil.
• Do not try to light any appliance.
• Do not touch any electrical switch; do
• Ne pas tenter d'allumer d'appareils.
• Ne touchez à aucun interrupteur. Ne pas
not use any phone in your building.
• Immediately call your gas supplier
from a neighbor's phone. Follow the
gas supplier's instructions.
• If you cannot reach your gas supplier,
call the fire department.
- Installation and service must be
performed by a qualified installer,
service agency or the gas supplier.
vous servir des téléphones dans le
bâtiment où vous vous trouvez.
• Appelez immédiatement votre
fournisseur de gaz depuis un voisin.
Suivez les instructions du fournisseur.
• Si vous ne pouvez rejoindre le
fournisseur de gaz, appelez le service
des incendies.
- L'installation et I'entretien doivent être
assuréx par un installateur ou un service
d'entretien qualifié ou par le fournisseur de
The following terms are used throughout this manual to bring attention to the presence of hazards of various risk levels.
Indicates a potentially hazardous situation which,
if not avoided, could result in death, serious injury
or substantial property damage.
Indicates a potentially hazardous situation which,
if not avoided, may result in moderate or minor
injury or property damage.
Basic Operation
There are no user serviceable parts on this boiler. Attempts to service this boiler by someone other than a
qualified gas service technician could void the warranty, cause property damage, personal injury or loss of
Should overheating occur or the gas supply fail to shut off, do not turn off or disconnect the electrical
supply to the pump. Instead, shut off the gas supply at a location external to the appliance.
En cas de surchauffe ou si I'admission de gaz ne peut étre coupée, ne pas couper ni débrancher
l'alimentation électrique de la pompe. Fermer plutôt le robinet d'admission de gaz à l'extérieur de I'appareil.
Do not use this boiler if any part has been under water. Immediately call a qualified service technician to
inspect the boiler and to replace any part of the control system and any gas control which has been under
Like all central heating appliances, this boiler is equipped with safety devices, which could cause it to
shutdown, requiring service to restore normal operation. Where such a shutdown could result in damage
from low temperatures (such as frozen pipes), do not leave the heating system unattended during cold
weather unless alarms or other safeguards are in place to prevent damage.
A. General
1. This manual covers the proper care and use of the
Alpine™ (ALP) Condensing High Efficiency Gas
Fired Boiler
2. Instructions to safely light and shut down this boiler
are shown on page 4, as well as on a label affixed to
the boiler. Control locations shown in Figure 1.
3. The Alpine™ (ALP) boilers use an electronic
means built into the ignition system to extinguish
the burner in the event that flames exit the
combustion chamber. If the boiler fails to fire, call
a qualified heating service agency to diagnose and
correct the problem.
4. Alpine™ (ALP) boilers – These boilers are
equipped with a safety feature which will shut down
the burner in the event that there is a blockage in
the vent system. In the event that the boiler fails to
function, and the boiler is vented through an outside
wall accessible from the ground, inspect the vent
terminal on the outside wall for a blockage such
as a bee’s nest or ice. If a blockage is found, the
burner should ignite approximately 30 seconds after
the blockage is removed. If no blockage is found,
or if the terminal is inaccessible from the ground,
the problem must be diagnosed and corrected by a
qualified gas service technician.
In the event that the ignition system on an ALP
boiler does not permit the boiler to fire, there is
either a problem with the ignition system or a
problem with the vent system. Call a qualified
gas service technician to diagnose and correct
the problem.
A shutdown of the burner due to the pressure
switch is an indication that there is a problem
with the vent system, such as a blockage. The
boiler pressure switch should only be reset
after a qualified gas service technician has
diagnosed and corrected the venting problem
that caused the blocked vent air proving switch
to open.
B. Maintenance
1. Safe reliable operation of this boiler depends upon
proper periodic maintenance.
2. The following should be done on a continuous
• Keep the area around the boiler free of objects,
which are flammable.
• Do not store or use sources of hydrocarbons such
as bleaches, fabric softeners, paints, cleaners,
refrigerants, and cat boxes near the boiler. Traces
of these chemicals can be drawn into the boiler,
causing severe corrosion damage to the boiler
and/or objectionable odors.
• Do not expose the boiler to large amounts of dust
such as that generated by dry wall construction
or woodworking.
3. A qualified gas service technician should perform
the maintenance procedure shown in the installation
manual on an annual basis.
4. The owner should visually inspect the venting
system on a monthly basis. If any of the following
conditions are found, the boiler should be shut down
and a qualified gas service technician called to
correct the problem before the boiler is placed back
in service:
• Loose joints, corrosion or other deterioration
• Condensate leakage
• Sags in horizontal runs of vent pipe
5. The owner should also perform a monthly visual
inspection of the boiler and the surrounding system
piping. To do this, remove the boiler jacket door.
If any of the following are found, a qualified gas
service technician should be consulted immediately:
• Deterioration of the visible controls, wiring, and
sheet metal components
• Heating system water Leaks
• Carbon (“soot”) in or near the burner
compartment area
• Make sure that the condensate drain system is
unobstructed and leak tight.
The Alpine™ (ALP) has a heat exchanger made
from a special stainless steel alloy which can
be severely damaged by frequent additions of
water or by the addition of boiler water additives
which are not designed for use with stainless
steel boilers. If it is necessary to add water to
the boiler, have a service technician check the
system for leaks. Do not add any chemicals to the
boiler not listed in Section X of the Alpine™ (ALP)
installation manual. Warranty is void if the service
and maintenance procedure shown in Section XII
of the Alpine™ (ALP) installation manual is not
Carbon (“soot”) in or near the burner compartment
area is an indication of a potential carbon
monoxide hazard. If carbon is found, the boiler
should be shut down immediately and inspected
by a qualified gas service technician. The cause
of the sooting should be found and corrected
before the boiler is restarted.
Figure 1: Control Locations (shown with optional concentric vent collar)
Alpine™ Series Lighting and Operating Instructions
Figure 2: Lighting Instructions
User Maintenance
Service on this boiler should be undertaken only by trained and skilled personnel from a qualified service
agency. Inspections should be performed at intervals specified in Installation, Operating and Service
Instructions and this manual. Maintain manuals in a legible condition.
Keep boiler area clear and free of combustible materials, gasoline and other flammable vapors and liquids.
Do not place any obstructions in boiler room that will hinder flow of combustion and ventilation air.
A. General Housekeeping (Continuous).
1. Keep boiler area clear and free of combustible
materials and obstructions to the free flow of
combustion and ventilation air to the boiler.
2. Do not store or use gasoline or other flammable
vapors or liquids in the vicinity of the boiler or any
other appliance.
3. Do not store or use sources of hydrocarbons in
the vicinity of the boiler. Sources of hydrocarbons
include bleaches, cleaners, chemicals, sprays, paint
removers, fabric softeners and refrigerants.
B. Inspect Concentric Inlet Air/Vent System (Monthly).
1. Concentric Inlet Air/Vent Terminal must be free
of obstruction and undamaged due to impact or
excessive temperature.
2. Concentric Inlet Air/Vent Terminal exterior wall
penetration must be weather tight.
3. Concentric Inlet Air/Vent pipe must be supported at
maximum 5 ft interval and must not sag.
4. All Concentric external Inlet Air pipe joints must be
secure and airtight.
5. All Concentric internal Vent pipe joints must be
secure, gas tight and watertight.
6. Condensate drain must be free of obstruction and
allow condensate to flow freely. If corrective action
is required, contact your installer or qualified service
C. Inspect burner Flames (Monthly).
1. Remove lower front door assembly.
2. Adjust thermostat to the highest setting to initiate
boiler firing.
3. View burner flames through observation glass.
4. Check burner flames. See Figure 3. On high fire
the flame should be stable and mostly blue. No
true yellow tipping should be present, however
intermittent flecks of yellow and orange in the
flame, caused by dust in air, are normal.
Figure 3: Burner Flame
5. If true yellow tipping is observed, follow
(see Figure 2) and contact your installer or qualified
service agency.
6. If burner flames look satisfactory, adjust thermostat
to the normal setting to stop boiler firing.
D. Schedule Inspection by Your Installer or Qualified
Service Agency (Annually or at Beginning of
Heating Season).
For continued safe operation either your installer, or a
qualified service agency must provide a more detailed
inspection of burner, heat exchanger, controls and
vent system and provide maintenance as specified in
Installation, Operating and Service Instructions.
All Alpine™ Series repair parts may be obtained through your local U.S. Boiler Wholesale distributor.
Should you require assistance in locating a U.S. Boiler distributor in your area, or have questions
regarding the availability of U.S. Boiler products or repair parts, please contact U.S. Boiler Customer
Service at (717) 481-8400 or Fax (717) 481-8408.
Important Product Safety Information
Refractory Ceramic Fiber Product
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.
AVOID Breathing Fiber Particulates and Dust
Precautionary Measures:
Do not remove or replace RCF parts or attempt any service or repair work
involving RCF without wearing the following protective gear:
1. A National Institute for Occupational Safety and Health (NIOSH)
approved respirator
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 classified as hazardous wastes in the United
States and Canada.
First Aid Procedures:
If contact with eyes: Flush with water for at least 15 minutes. Seek
immediate medical attention if irritation persists.
If contact with skin: Wash affected area gently with soap and water.
Seek immediate medical attention if irritation persists.
If breathing difficulty develops: Leave the area and move to a location
with clean fresh air. Seek immediate medical attention if breathing
difficulties persist.
Ingestion: Do not induce vomiting. Drink plenty of water. Seek
immediate medical attention.