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INSTALLATION, OPERATING AND
SERVICE INSTRUCTIONS FOR
™
Alliance SL
Indirect - Fired Water Heater
Including
Warranty
Information
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 Serial Number Installation Date
AL SL
Heating Contractor Phone Number
Address
U.S. Boiler Company, Inc.
Price - $5.00
00934-0R-/07
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GENERAL INFORMATION PLEASE READ INSTRUCTIONS CAREFULLY BEFORE INSTALLING WATER HEATER U.S Boiler Company, Inc. – Burnham Hydronics (herein called the Company) intends that this Alliance SL™ Indirect-Fired Water 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 through the internal coil in the tank. We specifically do not warrant this tank for high temperature applications such as wood stoves or steam
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INDEX General Information ..................................................................................................................... 2 Specifications & Ratings .............................................................................................................. 2 Installation Guidelines ................................................................................................................. 4 Installation Checklist ................................................
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INSTALLATION GUIDELINES A. INSPECTING AND PREPARING THE WATER HEATER 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 “Tee”, foamed lid and screws. q AL119SL - Remove the cardboard boxes, which come packaged with the heater. One box should contain the following: TPI thermostat, T&P valve and a “Tee”, foamed lid and screws. The other box should contain the heat exchanger. B
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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 any distance below the structural floor and cannot contact any live electrical parts. The discharge opening must not be blocked or r
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q Do not apply heat directly to the cold-water inlet as it is made of plastic and will melt. G. BOILER SUPPLY CONNECTIONS q WARNING: 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 water supply fittings on this heater are brass – do not over tighten or strip threads. q It is recommended to use a union as per Figures 1 and 2. NOTE: Be sure
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q Run all 24VAC wiring thru the square notch on bottom of TPI case. (See TPI Diagram 3) q Incoming 24VAC power must be connected to 24VAC 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 110V wiring) on the bottom left corner of TPI control. (See TPI Diagram 3) q All and only 110VAC wiring must go through an appropriate chase nipple installed in the knockout
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q Do not apply heat to cold inlet. q If there is a check valve (sometimes in water meter), backflow preventer or pressure-reducing valve, install an adequate size expansion tank. G. FILLING THE HEATER q Completely fill heater. q Water connections completed and free of leaks. q Check for proper installation of relief valve. q Close drain valve. q Open highest hot water faucet. q Open cold water inlet valve and fill system. H. WIRING See Figure 1 & 2 and separate TPI
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WATER TEMPERATURE CONTROLS A periodic inspection of the operating controls, heat exchanger and wiring should be made by qualified ser- vice personnel. Temperature of the water should be tested periodically at the faucet to be sure thermostat is working properly. TEMPERATURE ADJUSTMENT ® The TPI comes with a factory set temperature setting of 120°F and differential ® setting of 10°F. Any temperature adjustment of the thermostat must be made by qualified service personnel, as shown below.
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TPI CONTROL - DIAGRAM Indicating Light Temperature Adjust Differential Adjust TPI CONTROL - DIAGRAM Screw A 0
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TPI CONTROL - DIAGRAM 3 Outgoing 4V Incoming 4V wires to relay power or zone valve connection Outgoing 0V Incoming 4V wires to power circulator connections Chase Nipple Conduit NOTE: Use proper conduit and chase nipple
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FIGURE 1 - Installation Using Zone Valves Installation Diagram Using Zone Valves FIGURE 2 - Installation Using Circulator Installation Diagram Using Separate Circulator
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FIGURE 3 - Coil Detail & Tightening Sequence Bolt Small Large outside inside O-ring O-ring Steel Washer Coil Plate Plastic O-Ring Housing Tank Flange ‘L’ Nut Proper Tightening Sequence for Top Mount Coil 7 4 3 5 3 Incorrect Correct Note: Same as car tire lugs CAUTION: Does not require excessive force to seal properly. 3
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Circulator & Burner Control Wiring Diagrams Standard Wiring for Circulator with Boiler Maintaining a Temperature of 0° ® ® 20° 160° 150° 15° LowVoltage 140° 130° 10° 120Volts 120° 5° 110° Differential Temperature LED flashing green = calling for heat solid green = at temperature red = error Pump/TT 24v Probe L1 Hot 24v 120 Volts Switched Hot L2 Neutral Circulator Wiring for Burner Control L4E ® ® 20° 160° TV W T 150° 15° 140° 130° 10° Transformer Z 120° 5° 110° Thermostat Switching Relay D
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Zone Valve Wiring Diagrams Wiring for 3 Wire Zone Valve L o w V oltage ® ® 120 V olts 20 ° 160 ° 150 ° 15 ° 140 ° 130 ° 10 ° B oiler 120 ° C onnec tions 5 ° 1 10 ° T Differential T emperature LED T flashing green = calling for heat solid green = at temperature red = error P ump/T T 24v P r ob e 24v 2 3 1 Z one V alv e H ot N eutr al 120v Wiring for 4 Zone Valve ® ® 20 ° 160 ° 150 ° 15 ° 140 ° 130 ° 10 ° 120 ° 5 ° 1 10 ° Differential T emperature LED M ot
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Switching relay Wiring Diagrams Switching Relay R8845U or SR 501 Switching Relay SR-502 or SR-503 16
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Switching relay Wiring Diagrams (con’t) Switching Relay SR-504 with Priority Option ® ® 20 ° 160 ° 150 ° 15 ° 140 ° L o w V oltage 130 ° 10 ° 120 ° 120 V olts 5 ° 1 10 ° Differential T emperature LED flashing green = calling for heat solid green = at temperature red = error P ump/T T 24v P r ob e Z ONE 4 PRIORIT Y Z ONE 1 Z ONE 2 Z ONE 3 Z ONE 4 SR 504 ON OFF PO WER FOUR Z ONE SWIT CHING REL A Y WITH OPTIONAL PRIORIT Y Z ONE 1 Z ONE 2 Z ONE 3 120 V OL T REL A Y
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HOW TO OBTAIN SERVICE ASSISTANCE U.S. Boiler Company, Inc. – Burnham Hydronics does not have a service department or personnel to ser- vice your heater in the field. A qualified installer or service technician must do all service work. Therefore, if you have any questions about your new water heater concerning service adjustment, repair, routine main- tenance, or replacement - first contact your installer, plumbing contractor or service agency. In the event that the contractor, for whateve
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Alliance SL™ Indirect-Fired Water Heater 10/2/1 LIMITED WARRANTY Ten Year Limited Tank Replacement Warranty Two Year Limited Tank Replacement Labor Allowance One Year Limited Parts Warranty U.S. Boiler Company, Inc. – Burnham Hydronics, (hereinafter called the company) offers the following Lim- ited Tank Replacement Warranty, Limited Tank Replacement Labor Allowance, and Limited Parts Warranty to the original purchaser/owner of this stone-lined Alliance SL™ indirect-fired water heater. These w
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ONE () YEAR LIMITED PARTS WARRANTY DURATION: 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 workmanship or material. Subject to prior Company approval. COMPANY OBLIGATION: The warranty covers any component of the Alliance SL™ water heater proven to be
