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Price - $3.00
INSTALLATION, OPERATING
AND
SERVICE INSTRUCTIONS
TM
ALLIANCE SERIES
INDIRECT-FIRED WATER HEATERS
MODELS AL-26A, 40A, 53A, 79A and 119A
for SINGLE WATER
HEATER
INSTALLATIONS
For service or repairs to the water heater, call your heating contractor. When seeking information on water
heater, provide Model Number and Serial Number as shown on Rating Label.
Model Number Serial Number Installation Date
_ AL _______ _ _ _ _ _
Heating Contractor Phone Number
Address
®
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IMPORTANT INFORMATION - READ CAREFULLY NOTE: The equipment shall be installed in accordance with those installation regulations required 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 water heaters installed in the USA shall be in accordance with the National Electrical Code and/or local regulations. All wiring on water heaters installe
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I. General Information WARNING 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. Installation and service must be performed only by an experienced, skilled installer or service agency. Installation is not complete unless a pressure and temperature relief valve is installed into the side of the water heater. See Pip
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Table 1: Alliance Water Heater Dimension (Inches) ALLIANCE AB C D E F G H I J K MODEL AL26A 40 20-1/4 31-1/2 22-1/2 9-3/4 2 3/4 3/4 3/4 3/4 3/4 AL40A 55 20-1/4 46-1/2 25-3/4 9-3/4 2 3/4 3/4 3/4 3/4 3/4 AL53A 70-5/8 20-1/4 62-1/8 28-3/4 9-3/4 2 3/4 3/4 3/4 3/4 3/4 AL79A 69-3/8 23-3/4 60-7/8 29-1/4 10-1/4 1-5/8 1 3/4 3/4 1 1 AL119A 66 29-1/2 52-3/4 39-1/4 12-3/4 2-1/2 1-1/4 1-1/4 1-1/4 1-1/4 1 Table 2: Alliance Water Heater Capacities MAXIMUM TANK COIL DRY WET COIL HEAT HYDROSTATIC ALLIANCE ALLO
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CAUTION The heat transfer medium must be water or other non-toxic fluid having a toxicity rating or class of 1, as listed in clinical Toxicology of Commercial Products, 5th edition. The pressure of the heat transfer medium must be limited to a maximum of 30 psig by an approved safety or relief valve. NOTICE This water heater has a limited warranty, a copy of which is printed on the back of this manual. It is the responsibility of the installing contractor to see that all controls are correctly i
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Select a circulator which will provide at least the during simultaneous space and domestic hot water minimum flow rate at combined pressure drop. heating operations, depending on such factors as boiler output, boiler over sizing, number of space TM B. System Zone Control The Alliance water heating zones calling for heat and ratio of domestic heater must be installed as a zone separate from the hot water load to space heating load. space heating system. The domestic hot water zone's D. Component
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cool to room temperature, or if tank is drained inlet and outlet tappings. ® without opening a hot water faucet. A Watts Model No. N36 is an appropriate vacuum relief valve. 4. Thermal Expansion Tank If water heater is installed in a closed water supply system, such as one having a back-flow preventer in the cold water G. Water Quality Improper water quality will reduce line, provide thermal expansion control. Contact the expected life of the Alliance™ water heater. Hard the water supplier o
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III. Piping 3. Pipe relief valve discharge to floor. A. Drain domestic water system. 4. Connect from supply union to hot water supply 1. Shut off cold water supply at main shut-off valve. system using vacuum breaker, shut-off valve, and 2. Open one or more system faucets to relieve heat trap (to prevent thermal siphoning during non- pressure. Open system drain valve, leaving faucets draw periods). open to relieve vacuum. D. Connect cold water supply piping (see Figure 2). 3. Disconnect existing
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4. Purge air from domestic water system. Allow water 1. Determine where in the boiler and space heating to run so the tank is thoroughly purged of any piping system the Alliance™ connections should be debris. Run water long enough so that a minimum made by identifying the type of system from Figures of five (5) volume changes of the tank are 3 thru 6. accomplished. Close faucets. Reinstall screens. 2. In all cases, the Alliance™ connection labeled 5. Check system for leaks. Repair as necessar
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G. Connect water boiler supply piping (See Figures 3 thru 6). 1. For a space heating system that utilizes ZONE VALVES AND A BOILER BYPASS, refer to Figure 3. The Alliance™ connection labeled "BOILER SUPPLY" should be piped to the boiler supply piping as close to the boiler as possible and especially before the bypass piping. Mount the circulator as close as possible to the water heater making sure the flow arrow points toward the water heater. The use of a shut-off valve is recommended for fu
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3. For a space heating system that utilizes ZONE VALVES WITHOUT A BOILER BYPASS, refer to Figure 5. The Alliance™ connection labeled "BOILER SUPPLY" should be piped to the boiler supply piping after the air purger and before the space heating circulator. Mount the water heater circulator as close as possible to the water heater making sure the flow arrow points toward the water heater. The use of a shut-off valve is recommended for future service convenience. Figure 5: Water Boiler Piping wit
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valve is recommended for future service H. Connect steam boiler piping (See Figures 7 thru 10). convenience. The use of a flow control or check 1. Burnham V-7 Series steam boiler (Refer to Figure valve is required to prevent back flow through 7). the water heater during operation of the space heating system. a. For satisfactory supply of hot water, the V-7 steam boiler must be equipped with a special c. The Alliance™ connection labeled "BOILER tapped rear heater coil cover plate contained in SU
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Figure 8 3. Typical steam boiler with connections available boiler section furthest away from the return below the water line (Refer to Figure 9). tapping to prevent short circuiting in the boiler. This tapping should be high enough to provide a. The Alliance™ connection labeled "BOILER hot water but must be below the lowest RETURN" should be piped to a tapping in the permissible water level. The water heater boiler that is below the lowest permissible water circulator should be floor mounted w
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Figure 10 4. Steam boiler without hot water connections I. Fill boiler system. available below the water line (Refer to Figure 10). 1. On new boiler installations, do not purge the boiler a. Supplying the Alliance™ from the bottom or space heating system through the water heater. tappings in a steam boiler is not recommended During any boiler or space heating system flushing, due to insufficient water temperature, especially cleaning, or purging, the water heater should be during warmer months w
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IV. Electrical 1. Install electric wiring in accordance with National Electrical Code or the Canadian Electrical Code and local regulations. See Figure 11 for the wiring diagram and the boiler's Installation manual. 2. The Alliance™ models contain an aquastat assembly and will require an installer supplied double pole, single throw (DPST) relay with a normally open (NO) contact, a normally closed (NC) contact, and a 120 volt coil for priority domestic water. A Honeywell R4222D1013 is an appro
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V. Operation A. System Start-Up 2. For the most energy efficient operation, adjust aquastat for the minimum water temperature 1. Follow boiler installation instructions to place necessary to meet domestic hot water needs. boiler in operation. 2. Turn aquastat dial clockwise to desired setting. a. An initial setting of 120°F is recommended. b. Turning the knob clockwise from "100" position will cause an audible click indicating the desired temperature is higher than the current tank water temper
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VI. Service Instructions A. The Alliance™ is intended to provide a service life of which may drain out of the lines leading to the domestic uses. many years. Components that require service, however, may be subject to failure. Failure to use the 5. Drain the water heater until the water within the correct procedures or parts in these circumstances may tank is even with the top of the heat exchanger coil. make the water heater unsafe. The water heater cover plate should be removed from the tank
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VII. Trouble Shooting PROBLEM CAUSE SOLUTION No hot water at faucet Boiler does not operate Refer to boiler installation instructions Check main service switch Check fused disconnect Circulator does not operate Check power supply Check shaft coupling Improper aquastat setting or calibration Turn tank aquastat to higher setting Zone valve does not open (if used) Check power supply Electrical problem (relay, wiring, fuse, etc.) Check fuse and replace Check circuit breaker and reset (if applicable)
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VIII. Repair Parts 8010812 AL26A 1 Aquastat (Honeywell L4006A2114) 2 Handhole Cover 8050802 AL40A 8040808 3 Handhole Cover Gasket 8200804 7 Top Cover AL53A 4 Handhole Cover Bracket 8050803 AL79A 8040809 5 Handhole Cover Nut 8080804 AL119A 8040810 AL26A 8040803 AL26A AL40A 8040804 AL40A 8040811 8 Bottom Cover * AL53A 8040805 AL53A 6Jacket AL79A 8040806 AL79A 8040812 AL119A 8040807 9Plastic Rivet * 8040813 10 Double Sided Tape * 8040814 * Not applicable to AL119A 19
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All Alliance™ 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 your Burnham Regional Sales Office as listed below. Burnham Corporation Regional Offices A. Burnham Corporation - Central & Western Regions C. Burnham Corporation - Metropolitan Region P.O. Box 3079 P.O. Box 3079 Lancaster,
