Burnham 53A, 79A, Alliance AL-26A, ALLIANCE 119A, Alliance AL-40A Installation, Operating And Service Instructions

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Price - $3.00

INST ALLATION, OPERA TING

AND

SERVICE INSTRUCTIONS

TM

ALLIANCE

INDIRECT-FIRED WATER HEATERS

MODELS AL-26A, 40A, 53A, 79A and 119A

SERIES

for SINGLE W ATER
HEATER
INSTALLATIONS

For serv ice or repairs to the water heater, call your heating c ontractor. When s eek ing information on water
heater, provide Model N umber and Serial Number as shown on Rating Label.

Model Number

_ AL _____ __

Serial Number

_ _ _ _ _

Installation Date

Heating C ontractor Phone Number

Address

8140817R3-3/00

AMERICA’S BOILER COMPAN

BurnhamCorporation

1

Lancaster, PA 17604-307

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 installed in Canada shall be in accordance with the Canadian Electrical Code and/or local
regulations.

The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels,
or to important information concerning the life of the water heater.

DA NGER

Indicates an imminently hazardous situation
which, if not avoided, will result in death,
serious inju ry or substa ntial proper t y dama ge.

WARNING

Indicat es a potentia ll y hazardo us situ ation
which, if not avoided, could result in death,
serious injury or substantial property damage.

CAUTION

Ind icates a poten tially h aza rdous si tuation
which, if not avoided, may result in
moderate or minor injury or prop erty
damage .

NO TIC E

Indi cates spec ial ins truction s o n
ins tall ation, op e ratio n, or m ai nt enan c e
whi ch are impor tant b ut not relate d to
persona l injury ha zards .

DO NOT store or use gasoline or other flammable vapors or liquids in the vicinity of this or any
other appliance.
If you smell g as vapors, DO NOT try to o perate any ap pliance - DO NOT touch any electrical
switch or use any phone in the building. Immediately, call the gas supplier from a remotely
located phone. Follow the g as su pp lier's instructions or if the supplier is un availab le, contact the
fire department.

DA NGE R

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I. General Information

WAR N IN G

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
perfo rmed on ly by an exp erienced, s killed ins taller or serv ice ag ency.

Installation is not complete unless a pressure and temperature relief valve is installed into
the side of the water heater. See Piping Section of this manual for details.

This water heater contains very hot water under high pressure. D o not unscrew any pipe
fittings nor attempt to disconnect any components of this water heater w ithout positively
assuring the water is cool and has no pressure. Always wear protective clothing and
equipment when installing, starting up or servicing this water heater to prevent scald
injuries. Do not rely on the pressure and temperature gauges to determine the temperature
and pressure of the water heater. This water heater contains components which become
very hot when the boiler is operating. Do not touch any components unless they are cool.

Water heater materials of construction contain urethane, heavy metals and/or other toxic or
harmful substances which can cause death or serious injury and which are known to the
state of California to cause cancer, birth defects and other reproductive harm. Always use
proper safety clothing, respirators and equipm ent when servicing or working nearby this
water heater.

Failure to follow all instructions in the proper order can cause personal injury or death.
Read all instructions, including all those contained in component manufacturers' manuals
which are provided with the water heater before installing, starting up, operating, maintaining
or servicing.

NOTICE

The A lliance wa ter hea ter must be installe d with a pre ssure a nd tempe rature relief valve. Th e
valve is not supplied with the water heater and must be provided by the installer.

T able of Contents

Section I - General Information ............................ 3

Ratings, Capacities, Weights, & Dimensions....... 4

Section V - Operation.......................................... 16

Section VI - Service Instructions ........................ 17

Section II - Pre-Installation................................... 5

Section III - Piping ................................................ 8

Section IV - Electrical ......................................... 15

Section VII - Trouble Shooting........................... 18

Section VIII - Repair Parts.................................. 19

Warranty ..............................................Back Cover

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Table 1: Alliance Water Heater Dimension (Inches)

ALLIANCE

MOD EL

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
AL7 9A 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

ABCDEFGH I JK

Table 2: Alliance Water Heater Capacities

M AXIMU M

ALLOWA BLE

WOR KI NG

P RESSUR E ( PSI)

HYDROSTATIC

DESIGN

P RESSUR E ( PSI)

ALLI ANC E

MOD EL

TANK

VOL UME

(GA L )

COIL

VOL UME

(GA L )

DRY

WEIGHT

(LBS)

WET

WEIGHT

(LBS)

COIL HEAT
TRANSFER

AREA ( SQ. F T. )

AL26A 26.4 1. 0 49 269 6.5 150 300
AL40A 39.6 1. 2 66 396 8.6 150 300
AL53A 52.8 1. 4 82 522 9.7 150 300
AL79A 79.3 2. 2 170 831 15.1 150 300

AL119A 119.4 2.9 183 1178 24.3 150 300

Table 3: Alliance Water Heater Performance

MAXIMUM FIRST

MO DEL

AL2 6A 142 197 1.93 2.84 110,000 8.0 2.5 2.4
AL4 0 A 175 242 2.26 3.38 133,000 11.4 6.1 7.2
AL5 3 A 224 310 2.85 4.29 164,000 10.9 6.5 9.0
AL7 9 A 253 350 2.90 4.51 190,000 10.6 8.4 9.1

AL11 9A 350 409 3.84 4.83 386,000 15.4 11.6 16.4

NOTES:

tank (when applicable).

HO UR RAT ING

GAL/HR @

14 0F 115F 14 0F 115F

All ra tings based o n 200F bo iler w ate r tem pera ture, 50F d omestic w ater inlet tempera ture, and a fully recovered

CONTINUOUS

RATING

GAL/MIN @

BOILER D OE

H E AT IN G C A PA CI TY

NEEDED FOR

R ATING S (BTU/HR )

MINIMUM BOILER

WATER FLO W

THROUGH HEATER

C O IL ( GA L / M IN )

PRESSURE

DRO P THROUGH

COIL AT MIN.

FLOW (F T. W .C .)

MINUTES OF

140F WATER
AVAILABLE AT
5 GPM DRAW

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CA UTION

The heat transfer m edium must be water or other non-toxic fluid having a toxicity rating or class
of 1, as listed in clinical Toxicolog y of Commercial Products, 5th edition.
The pressur e of the heat tran sfer m edium must be limited to a maxim um of 30 psig b y an
approved safety or relief valve.

NOTICE

This water heater has a limited warranty, a copy of which is printed on the back o f this m anu al.
It is the respon sibility of the in stalling cont ractor to see th at all contro ls a re correctly installed
and are operating properly when the installation is complete.

II. Pre-Installation

Inspect shipment carefully for any sign of damage. All
equipment is carefully manufactured, inspected and
packed. Burnham Corporation's responsibility ceases
upon delivery of water heater to the carrier in good
condition. Any claim for damage or shortage in
shipment must be filed immediately against the carrier
by the consignee. No claims for variances or shortages
will be allowed by Manufacturer, unless presented
within sixty (60) days after receipt of equipment.

Installation must conform to the requirements of the
authority having jurisdiction. In the absence of such
requirements, installation must conform to National
Plumbing Code and National Electrical Code,
ANSI/NFPA No. 70, current edition.

present.
Consult Burnham for size recommendations for

installation with unusual water demand.
Refer to Table 3 for water heater performance

specifications.

2. Boiler DOE Heating Capacity The Alliance™

water heater will provide the rated performance
only if used in conjunction with a boiler with a
DOE heating capacity at least as much as the
minimum noted in Table 3. If the boiler has less
capacity, the output of the tank will be reduced. To
determine the approximate reduction in output from
the tank use the following formula:

IMPORTANT DECISIONS REQUIRED BEFORE
INSTALLATION:

A. Sizing

1. Alliance™ Model - Choose the Alliance™ model

based on the expected water usage of the building.
The average residence with one shower or more
will require a model AL40A or larger. The AL26A
should only be considered for residences with
minimal water demand or for commercial
application where showers are not present.

Factors which dramatically increase water demand
include high flow shower heads, whirlpool tubs,
and the use of multiple showers at the same time.
Upsize the tank size if any of these factors are

For example, what would the first hour rating be if
a model AL53A were installed with a boiler having
a DOE heating capacity of 120,000 BTU/h?

Increasing the boiler DOE heating capacity above
the values listed in Table 3 will not increase the
rating of the water heater.

3. Circulator Sizing - Refer to Table 3 for the

minimum flow rate through the water heater coil
and the corresponding pressure drop through the
coil. Calculate the pressure drop of all straight pipe
and fittings on the supply and return of the water
heater at the minimum flow rate. Add the piping/
fitting pressure drop to the pressure drop through
the water heater coil.

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Select a circulator which will provide at least the
minimum flow rate at combined pressure drop.

B. System Zone Control The Alliance

heater must be installed as a zone separate from the
space heating system. The domestic hot water zone's
piping and circulator must be sized for a minimum
flow rate with all zones in use and a maximum flow
rate with only the water heater in use. For this reason,
the preferred method of zone control is with
circulators.

1. Circulators - With space heating zones using

circulators, the Alliance™ should be added as an
additional zone with a circulator.

2. Zone Valves - Select a valve with low pressure

drop to assure adequate flow through the water
heater.

3. Hybrid - The space heating zone can be zoned

using zone valves and Alliance™ zoned with a
circulator. Refer to Figures 3 and 5.

TM

water

C. Domestic Hot Water Priority Two options are

available, Priority and Non-Priority.

during simultaneous space and domestic hot water
heating operations, depending on such factors as
boiler output, boiler over sizing, number of space
heating zones calling for heat and ratio of domestic
hot water load to space heating load.

D. Component Location

1. Alliance™ Location

When such a location cannot be avoided, a suitable
drain pan must be installed under the water heater.
The drain pan must be connected to a drain.

Adequate clearance from combustible materials and
for service must be provided.

1. Priority Demand for space heating is interrupted

or postponed until the domestic hot water demand
is satisfied. This option provides maximum delivery
of domestic hot water. Priority is recommended
when:

a. Boiler net output is 100,000 Btu per hour or

less, or

b. When boiler output required to satisfy domestic

hot water demand is at least 50% of the boiler
output required to satisfy space heating demand,
or

c. When an interruption in space heating can be

tolerated during a long domestic hot water draw.

The delay in space heating may not be noticed due
to the fast recovery time of the AllianceTM water
heater. Certain water heater system malfunctions
(such as domestic hot water zone circulator failure)
could delay space heating indefinitely.

When zoning with zone valves, priority can be
provided with a three-way valve. Carefully size the
valve for proper flow to all zones.

The AllianceTM is design certified for installation on
combustible flooring.

The Alliance™ may be installed in a closet or
alcove.

2. Boiler Location - Locate the boiler as close to the

Alliance™ as practical.

3. Fixture Locations - For fastest delivery of hot

water, place AllianceTM close to points of use.

E. Additional Recommended Components

2. Non-Priority Boiler output is divided between

space heating and domestic hot water heating.
Delivery of domestic hot water can be reduced

1. Shut-off Valves - Allows isolation of water heater

from domestic water system and/or boiler system
during service.

2. Unions - Allows water heater movement during

service if adequate clearance cannot be provided.

3. Vacuum Breaker - Protects water heater's tank

from possible collapse if a hot tank is allowed to

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cool to room temperature, or if tank is drained
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
line, provide thermal expansion control. Contact
the water supplier or local plumbing inspector for
additional information. An Amtrol Model ST-12 is
an appropriate diaphragm style thermal expansion
tank for most installations.

F. Removal of Existing Domestic Water

Heating System

1. External Tankless Heater - Disconnect from

boiler piping and domestic water system.

2. Tankless and Storage Heaters - Disconnect from

domestic water system. Heater does not need to be
removed from boiler. If left in place, do not plug

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inlet and outlet tappings.

G. Water Quality Improper water quality will reduce

the expected life of the Alliance™ water heater. Hard
water, sediment, high or low water Ph, and high levels
of chlorides in the domestic water should be avoided.
Sediment and hard water will coat the water heater coil
surfaces and reduce the rating of the water heater and
may, eventually, cause a failure. High or low Ph and/
or high chloride concentrations will cause the stainless
steel water heater components to corrode and
eventually fail. A filter is strongly recommended
where sediment is present in the water. A water
softening system is recommended for areas with hard
water.
In areas where water quality is unknown, a water
quality test should be performed.

WARN I N G

Do not operate ALLIANCE™ water heater in areas where water Ph is above 8.0 or below 6.0,
and/or with chloride concentra tions g reater than 80 parts p er million (pp m). Bu rnham' s Standard
Warranty does not cover problems caused by improper water Ph or excessive levels of chlorides.

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