Burnham Indirect - Fired Water Heater AL SL manual

1 INST ALLA TION, OPERA TING AND SER VICE INSTRUCTIONS FOR Alliance SL ™ Indirect - Fired W ater Heater For service or repairs to the water heater , call your heating contractor . When seeking informa- tion on the water heater , provide Model Number and Serial Number as shown on Rating Label. Model Number AL SL Serial Number Installation Date Hea[...]

2 PLEASE READ INSTRUCTIONS CAREFULL Y BEFORE INST ALLING W A TER HEA TER U.S Boiler Company , Inc. – Burnham Hydronics (herein called the Company) intends that this Alliance SL™ Indirect-Fired W ater Heater be used as a separate zone to a heating system boiler . This appliance is designed to heat water by circulating water from the boiler throu[...]

3 INDEX General Information ..................................................................................................................... 2 Specications & Ratings .............................................................................................................. 2 Installation Guidelines ...................................[...]

4 A. INSPECTING AND PREP ARING THE W A TER HEA TER  q AL27SL thru AL70SL - Remove the cardboard box, which comes packaged with the heater . It should contain the following: TPI thermostat, T&P valve and a “T ee”, foamed lid and screws. q AL1 19SL - Remove the cardboard boxes, which come packaged with the heater . One box should con[...]

5 valve must be marked with maximum set pressure not to exceed the marked maximum allowable working pressure of the water heater (150psi). Install the valve into the opening provided and marked for this purpose in the water heater , and orient it or provide the tubing so that any discharge from the valve will exit only within 6 inches above, or at [...]

6  q Do not apply heat directly to the cold-water inlet as it is made of plastic and will melt. G. BOILER SUPPL Y CONNECTIONS  q W ARNING: Boiler temperature must be controlled by the boiler high limit not to exceed 200°. Failure to do so will create a hazardous installation and void the applicable limited warranties.  q All wate[...]

7  q Run all 24V AC wiring thru the square notch on bottom of TPI case. (See TPI Diagram 3)  q Incoming 24V AC power must be connected to 24V AC connectors on the bottom right corner of TPI control. (See TPI Diagram 3)  q Connect control wiring to PUMP/TT normally open relay connections (rated for both 24V and 1 10V wiring) on the[...]

8  q Do not apply heat to cold inlet.  q If there is a check valve (sometimes in water meter), backow preventer or pressure-reducing valve, install an adequate size expansion tank. G. FILLING THE HEA TER  q Completely ll heater .  q W ater connections completed and free of leaks.  q Check for proper installation [...]

9 W A TER TEMPERA TURE CONTROLS A periodic inspection of the operating controls, heat exchanger and wiring should be made by qualied ser - vice personnel. T emperature of the water should be tested periodically at the faucet to be sure thermostat is working properly . TEMPERA TURE ADJUSTMENT The TPI comes with a factory set temperature setting o[...]

10 TPI CONTROL - DIAGRAM 1 Indicating Light T emperature Adjust Differential Adjust TPI CONTROL - DIAGRAM 2 Screw A[...]

1 1 TPI CONTROL - DIAGRAM 3 Outgoing 24V wires to relay or zone valve Incoming 24V power connection Outgoing 1 10V wires to circulator Chase Nipple Conduit Incoming 24V power connections NOTE: Use proper conduit and chase nipple[...]

12 FIGURE 1 - Installation Using Zone V alves Installation Diagram Using Zone V alves FIGURE 2 - Installation Using Circulator Installation Diagram Using Separate Circulator[...]

13 FIGURE 3 - Coil Detail & T ightening Sequence Bolt Steel W asher Coil Plate Plastic O-Ring Housing T ank Flange ‘L ’ Nut Small outside O-ring Large inside O-ring Proper T ightening Sequence for T op Mount Coil CAUTION: Does not require excessive force to seal properly . 3 2 1 6 4 7 2 5 3 8 1 Incorrect Correct Note: Same as car tire lugs[...]

14 Low V oltage 120 V olts L1 Hot 120 V olts L2 Neutral Circula tor 24v T emperature Differential Pump/TT 24v LED flashing green = calling for heat solid green = at temperature red = error 20° 15° 10° 5° 160° 150° 140° 130° 120° 1 10° Probe Switched Hot ® ® T T Switching Relay T ransformer Thermostat Burner T V W T Z C1 C2 L1 L2 B1 B2 1[...]

15 Zone V alve Wiring Diagrams Wiring for 3 W ire Zone V alve L o w V oltage 120 V olts 120v 24v B oiler C onnec tions T 1 T 2 3 H ot N eutr al Z one V alv e 120v 24v T o B oiler C onnec tions /C ir cula t or H ot N eutr al 4 W ir e Z one V alv e M ot or E nd S wit ch T T T emperature Differential P ump/T T 24v LED flashing green = calling for heat[...]

16 Switching relay Wiring Diagrams Switching Relay SR-502 or SR-503 Switching Relay R8845U or SR 501[...]

17 Switching relay Wiring Diagrams (con’t) Switching Relay SR-504 with Priority Option L o w V oltage 120 V olts FUSE 1 AMP C OM / 24 V A C FOUR Z ONE SWIT CHING REL A Y WITH OPTIONAL PRIORIT Y Z ONE 1 Z ONE 2 Z ONE 3 Z ONE 4 Z ONE 4 PRIORIT Y ON OFF Z ONE 1 Z ONE 2 Z ONE 3 Z ONE 4 PO WER 120 V OL T CIR CUL A T ORS X X END SWIT CH Z C ZR INPUT SR[...]

18 HOW T O OBT AIN SER VICE ASSIST ANCE U.S. Boiler Company , Inc. – Burnham Hydronics does not have a service department or personnel to ser- vice your heater in the eld. A qualied installer or service technician must do all service work. Therefore, if you have any questions about your new water heater concerning service adjustment, repair[...]

19 Alliance SL™ Indirect-Fired W ater Heater 10/2/1 LIMITED W ARRANTY T en Y ear Limited T ank Replacement W arranty T wo Y ear Limited T ank Replacement Labor Allowance One Y ear Limited Parts W arranty U.S. Boiler Company , Inc. – Burnham Hydronics, (hereinafter called the company) offers the following Lim- ited T ank Replacement W arranty , [...]

20 ONE (1) YEAR LIMITED P ARTS W ARRANTY DURA TION: The warranty is effective for one (1) year beginning with the date of original purchase. This warranty shall begin from the date of manufacture as indicated by the serial number . COVERAGE: The warranty covers any component part of the Alliance SL™ water heater proven to be defective in workmans[...]

21 MODEL & SERIAL NUMBER INFORMA TION The following information should be noted At time of installation and retained for Future reference. Model No. Serial No. Date Installed Dealer ’s Name Address City State Zip U.S. Boiler Company , Inc., – P .O. Box 3079 – Lancaster , P A 17604 www .burnham.com[...]

22 NOTES[...]

23 NOTES[...]

24 Optional Lifetime W arranty Registration Card A vailable to Residential, Single Family Homes Only Y es, I wish to purchase the Optional Lifetime W arranty! DA TE _____________________________________________________________________ PURCHASER’S NAME _______________________________________________________ HOME ADDRESS ___________________________[...]