Service & Installation Manual
Contents
1. SHUT OFF BACKFLOW PREVENTER EXPANSION TANK NOTES THIS DRAWING IS MEANT TO SHOW SYSTEM PIPING CONCEPT ONLY INSTALLER IS RESPONSIBLE FOR ALL EQUIPMENT AND DETAILING REQUIRED BY LOCAL CODES DI ELECTRIC UNIONS MUST BE USED ON THE TANK CONNECTIONS TO PREVENT GALVANIC CORROSION ALLIED ENGINEERING COMPANY EP P 316 00 NOTES THIS DRAWING IS MEANT TO SHOW SYSTEM PIPING CONCEPT ONLY INSTALLER IS RESPONSIBLE FOR ALL EQUIPMENT AND DETAILING REQUIRED BY LOCAL CODES DI ELECTRIC UNIONS MUST BE USED ON THE TANK CONNECTIONS TO PREVENT GALVANIC CORROSION PIPING SYSTEM FOR EP TANKS RADIANT FLOOR BASEBOARD USING CIRCULATOR AND DOMESTIC HOT WATER PRIORITY ALLIED ENGINEERING COMPANY EP P 317 00 EPP SERIES INDIRECT WATER HEATERS Installation and Service Manual Double Coil for larger hot water demand RELIEF NOTES VALVE THIS DRAWING IS MEANT TO SHOW SYSTEM PIPING CONCEPT ONLY INSTALLER IS RESPONSIBLE FOR ALL EQUIPMENT AND DETAILING REQUIRED BY LOCAL CODES AIR DI ELECTRIC UNIONS MUST BE USED ON THE TANK CONNECTIONS TO ELIMINATOR PREVENT GALVANIC CORROSION BACKFLOW EXPANSION PREVENTER TANK COLD WATER FILL PIPING SYSTEM FOR EP TANKS ALLIED ENGINEERING COMPANY DEDICATED SINGLE BOILER WITH DOUBLE COIL TANK EP P 318 00 RELIEF NOTES VALVE THIS DRAWING IS MEANT TO SHOW SYSTEM PIPING CONCEPT ONLY INSTALLER IS RESPONSIBLE FOR ALL EQUIPMENT AND DETAILI2. INSTALLATION AND SERVICE MANUAL EPP SERIES INDIRECT WATER HEATERS FOR MODELS EPP 40 TO EPP 120 SEE REAR COVER FOR INDEX NWARNING Read this instruction manual before installation operation or service Failure to follow the instructions in this manual may result in severe personal injury death or substantial property damage Installation and service must be performed by a qualified service technician Manufactured by Allied Engineering Company Division of E Z Rect Manufacturing Ltd Manufacturers of Gas and Electric Boilers Stainless Steel Tanks Heat Exchangers and Electric Boosters 94 Riverside Drive North Vancouver B C V7H 2M6 e Telephone 604 929 1214 FAX 604 929 5184 Branches Calgary e Edmonton e Toronto PN5242745 Price 5 EPP SERIES INDIRECT WATER HEATERS Installation and Service Manual DIMENSIONS AND SPECIFICATIONS Storage Sizes Nominal Features Quality Construction 40 5 40 US Gal Fast Recovery Time 316L Stainless Steel Tank 60 5 60 US Gal Highest Heat Transfer Efficiency 316L Stainless Steel Heat Exchanger EPP 60 SCR 60 US Gal EPP 60 DC 60 US Gal Low Standby Heat Loss Aquastat and Stainless Steel Thermowell EPP 80 SC 80 US Gal Easy Installation Magnesium Anode EPP 80 DC 80 US Gal e Warranty 10 Year for Residential e Passivated for additional Corrosion Protection EPP 120 SC 120 US Gal See warranty
3. 120 Vac Bee WEE O Om GROUND p tree ON THE BOILER Qo CONTROL PANEL E Lu Iur qi wl E l fad IR t ms get n HCH weg NOTE l t L 1 PRIORITY TO ZONE 1 3 ER TANK AQUASTAT TH1 1 t TANK PUMP ZONE PUMP 1 l scd e Qi d 120 Vac EE Ee EE HITE WIRING DIAGRAM FOR EP TANKS ALLIED ENGINEERING COMPANY PUMPS WITH ZCB PRIORITY DHW EP W 004 00 15 EPP SERIES INDIRECT WATER HEATERS Installation and Service Manual WIRING LEGEND e FACTORY WIRING NEC CLASS LAS FACTORY WIRING NEC CLASS II FIELD WIRING NEC CLASS FIELD WIRING NEC CLASS II JUMPER J1 AND J2 INSTALLED INSTALLED INSTALLED J2 JUMPER SETTING DETAIL ZONE CONTROL BOARD PLUG TRANSFORMER 120 Vac 24 Voc 120 Vac GROUND ON THE BOILER CONTROL PANEL PRIORITY TO ZONE 1 TANK AQUASTAT TH1 TANK PUMP ZONE PUMP 2 TANK DHW WIRING DIAGRAM FOR EP TANKS DEDICATED SINGLE BOILER WITH SINGLE TANK ALLIED ENGINEERING COMPANY EP W 005 00 16 EPP SERIES INDIRECT WATER HEATERS Installation and Service Manual 40 STARTUP AND ADJUSTMENT ISCH Before filling the tank make sure that the T amp P relief valve is installed and that the unit is properly grounded CAUTION Never use tank until it is filled with water and connected to the domestic water piping and boiler piping 41 PRE
4. Relief Valve Possible Cause Tank control failure Solution Check wiring and power supply Replace control Aquastat not calling for heat Check wiring Replace aquastat Air lock in domestic water loop Purge and bleed piping Circulator not operating Repair or replace circulator Zone valve not operating Check wiring and power supply open manually to check Replace zone valve Boiler not operating Aquastat setting too low Boiler control too low Check wiring Check disconnect switch Check fuse or circuit breaker Check wiring and power supply Adjust aquastat to higher setting Defective aquastat or improper calibration Replace aquastat Undersized water heater Install adequate water heater Undersized boiler with no priority to domestic hot water Undersized boiler with no priority to domestic hot water Rewire for priority check sizing Rewire for priority check sizing Inadequate boiler water flow Check circulator sizing Ensure valve is open Purge and bleed piping Circulator capacity too low Replace circulator with correct one Scale build up in tank Aquastat setting too high Chemical cleaning or repeated flushing Adjust aquastat to lower setting Aquastat continuously runs Check wiring Replace aquastat Improper system piping and or control Check piping and flow control valve Improper system wiring Check wiring
5. Tempering mixing valve Inlet cold water pressure too high Read valve instructions or consult with manufacturer Install pressure reducing valve Excessive water pressure when heating Install proper thermal expansion tank on cold water inlet Relief valve leaking e Replace relief valve 21 EPP SERIES INDIRECT WATER HEATERS Installation and Service Manual 8 0 NOTES 22 EPP SERIES INDIRECT WATER HEATERS Installation and Service Manual 23 EPP SERIES INDIRECT WATER HEATERS Installation and Service Manual 9 0 INDEX Section Paqe DIMENSIONS AND 2 1 0 PRE INSTALLATION Dear Roca ncm EEN usss ua 3 1 1 REGEIVING Soh tect EEN 3 1 2 INSTALLATION CODES AND REQUIREMENTS 3 1 3 EEIT ORLON mev 3 1 4 OPERATING RESTRICTIONS a PE Teese aa e V Eg 4 1 5 WATER QUALITY S Z a yaka Sht e u e Pee desc OR E 4 2 0 PIPING AND PLUNMBING geseet EES ele eet alee 5 2 1 BOILER SIDE PEUMBING uuu uuu uuu an 5 2 2 INSTALLATION 6 2 3 DOMESTIC SIDE PLU MBIN G 10 2 4 T amp P RELIEF VALVE PLUMBING ccccccecccecc
6. 24 1 8 60 5 16 34 34 kt d 182 LB EPP 60 SCR 27 1013 16 275 16 363 8 34 34 1 le 164 LB EPP 60 DC 21 7 5 8 24 1 8 605 16 301 8 46 5 8 34 34 T 1 196 LB 80 5 23 10 1 4 26 3 4 635 16 1 ies ly ls 198 LB EPP 80 DC 23 10 1 4 26 3 4 635 16 327 8 49 1 4 1 1 1 1 212LB EPP 120 SC 27 1011 16 273 16 645 8 1 WE 1 WE le 15 236 LB EPP 120 DC 27 1011176 273 16 64 5 8 333 16 4911 16 1 112 1 1 256 LB Anode for EPP 60 SCR located at bottom of tank instead of top Also available e Stacker Indirect Fired Hot Water Tank in 40 US gallon boiler be stacked on casing to save floor space EPP Storage Tanks in 40 60 80 and 120 US gallon The Super Hot product improvement program may result in changes to design and or specifications being made without notice EPP SERIES INDIRECT WATER HEATERS Installation and Service Manual 1 0 PRE INSTALLATION 1 1 RECEIVING INSPECT SHIPMENT FOR POSSIBLE DAMAGE All goods are carefully manufactured inspected checked and packed by experienced workers The manufacturer s responsibility ceases upon delivery of goods to the carrier in good condition Any claims for damage and or shortage in shipment or non delivery must be filed immediately against the carrier by the consignee Use care when receiving and unpacking the tank Dropping the tank may cause damage and preve
7. START UP CHECKLIST a relief valve is properly installed and drain discharge is directed away to a drain Domestic cold and hot water lines are correctly connected to domestic water system a Boiler supply and return piping is correctly connected from boiler to the tank Domestic and boiler water systems are correctly pressurized Q All wiring is installed correctly no exposed high voltage wiring is present and the unit is properly grounded 4 2 STARTUP INSTRUCTIONS 1 Make sure all electrical power is OFF 2 Close the drain valve on tank 3 Open domestic water supply valve 4 Open the closest hot water faucet to vent air from the system 5 Close faucet when there is a constant flow of water 6 For boiler side piping follow boiler instructions to purge air 7 The tank domestic water piping and boiler water piping should be completely filled with water and all air extracted from both domestic and boiler water systems 8 Set aquastat on water heater An initial setting of 120 F 49 C is recommended The aquastat is adjusted to its lowest temperature setting when shipped from the factory 9 Power up boiler following boiler instructions and water heater 10 Check boiler is operating normally 11 Check zone valve or circulator is in good condition 12 Check all connections fittings and piping for leaks 13 Adjust the temperature at the faucets as described in the next section EPP SERIES INDIRECT WATER HEATERS Installa
8. for details EPP 120 DC 120 US Gal Note Single Coil heat exchanger uses 1 O D x 30 ft long Stainless Steel tube SC Single Coil Maximum Operating Pressure 150 psi DC Double Coil Maximum Tank Temperature 150 F SCR Crawl Space Design Single Coil Maximum Coil Temperature 210 F Recovery Based on Boiler Flow Rate of 10 GPM st H st A Inlet From 1 10 Min I Hour Continuous Thermal Input Delivery Delivery Delivery Model Number Boiler Requirements Temp F 135 F 135 F 115 F Btu Hr P US Gal US Gal US GPH eh EPP 40 SC 200 66 194 226 129 000 190 63 176 205 117 000 180 60 159 184 105 000 EPP 60 SC 200 86 214 226 129 000 190 83 196 205 117 000 1 1 2 180 80 179 184 105 000 dee EPP 60 SCR 200 86 214 226 129 000 1 2 190 83 196 205 117 000 AQUASTAT 180 80 179 184 105 000 COUPLING EPP 60 DC 200 102 313 383 219 000 190 97 284 346 198 000 180 92 253 309 176 000 EPP 80 SC 200 105 232 226 129 000 190 102 215 205 117 000 180 100 198 184 105 000 EPP 80 DC 200 122 333 383 219 000 190 117 304 346 198 000 180 112 273 309 176 000 EPP 120 SC 200 146 274 226 129 000 190 143 256 205 117 000 180 140 239 184 105 000 EPP 120 DC 200 163 375 383 219 000 190 157 345 346 198 000 180 152 314 309 176 000 Dimensions Fitting Sizes Weight E F G H I J A B C D Hot Water Cold Inlet from Outlet to Outlet Water Inlet Boiler Boiler EPP 40 SC 21 7 5 8 24 1 8 42 5 16 34 34 1 ile 144 LB EPP 60 SC 21 7 5 8
9. of the tank is based on the temperature and flow rate from the boiler supply To ensure that the minimum flow rate is provided use at least 1 inch pipe size from boiler to tank and a zone valve with a minimum 1 inch diameter and flow coefficient of at least Cy 8 Hot Water Priority A boiler system connected to multiple zones may be installed so that domestic water heating will be given priority over other zone heating If hot water priority is used preventative measures must be taken to ensure hot water priority during cold weather conditions does not result in freezing damage to the other zones Sample Systems Although there are unlimited possibilities for your indirect water heater system some typical installations are described and shown below Note that all heating zones can be controlled either by using circulators pumps or zone valves as long as correct flow is provided a Dedicated Single Boiler with Single Coil Tank Radiant Floor Baseboard with 3 Port Zone Valve Domestic Priority Radiant Floor Baseboard with 2 Port Zone Valve Domestic Priority Radiant Floor Baseboard Using Circulator and Domestic Hot Water Priority Dedicated Single Boiler with Double Coil Tank Radiant Floor or Hot Tub Pool Using Double Coil Tank Multiple Water Heaters Domestic Priority a Multiple Water Heaters Piped in Series UUUUUU Standard Circulators Zone Run the same as a standard heating zone except one zone is piped to t
10. 1 G aor Lili QI IH rN I l 11 1 TE E EN YY RR YY RR m T eal E E A ES ach vee M E oe LlIlll ZONE VAVES WITH ZCB PRIORITY DHW 14 ALLIED ENGINEERING COMPANY EP W 002 00 EPP SERIES INDIRECT WATER HEATERS Installation and Service Manual WIRING LEGEND c FACTORY WIRING NEC CLASS FACTORY WIRING NEC CLASS II FIELD WIRING NEC CLASS FIELD WIRING NEC CLASS II Ji INSTALLED NOT INSTALLED JUMPER SETTING DETAIL BLACK GE Ani OPTIONAL PUMP ZONE CONTROL BOARD PLUG TRANSFORMER 120 Vac 24 Vac 2 5 A FUSE L1 B 120 Vac 12 GROUND ON THE BOILER ESCH CONTROL PANEL RLY d RLY 8 8 ER 1 1 1 1 EL NOTE l NON PRIORITY TO ZONE 1 120 Vac E Is ONO d Se TANK AQUASTAT TH1 LORS SSSR ZONE PUMP 1 WIRING DIAGRAM FOR EP TANKS ALLIED ENGINEERING COMPANY PUMPS WITH ZCB NON PRIORITY DHW EP W 003 00 WIRING LEGEND c FACTORY WIRING NEC CLASS FACTORY WIRING NEC CLASS II FIELD WIRING NEC CLASS FIELD WIRING NEC CLASS Il J1 INSTALLED NOT INSTALLED JUMPER SETTING DETAIL ZONE CONTROL BOARD PLUG TRANSFORMER 120 Vac 24 Vac 2 5 A FUSE L1
11. 1 l I 1 1 I I I I I L E E 4 I I BOILER 24 VAC 1 I I CONNECTIONS Le es he dee eras eae done mee WIRING DIAGRAM FOR EP TANKS ALLIED ENGINEERING COMPANY ZONE VALVE NON PRIORITY DHW EP P 326 00 EPP SERIES INDIRECT WATER HEATERS Installation and Service Manual HIGH VOLTAGE 120 VAC FIELD WIRING LOW VOLTAGE 24 VAC FIELD WIRING TANK SPACE HEATING SPACE HEATING AQUASTAT THERMOSTAT THERMOSTAT ON OFF SWITCH AM oo 0 120 VAC NORMALLY CLOSED RELAY N TO BOILER 24 VAC CONNECTIONS WIRING DIAGRAM FOR EP TANKS ALLIED ENGINEERING COMPANY ZONE VALVE PRIORITY DHW EP P 327 00 HIGH VOLTAGE 120 VAC FIELD WIRING LOW VOLTAGE 24 VAC FIELD WIRING TANK SPACE HEATING SPACE HEATING AQUASTAT THERMOSTAT THERMOSTAT I ON OFF FUSE SWITCH I H I I 120 VAC N O I I I I 3 WAY ZONE VALVE SoS ae z TO BOILER 24 VAC THERMOSTAT CONNECTIONS 1 rm re rm rm eee ee ee ee ee ee eee WIRING DIAGRAM FOR EP TANKS ALLIED ENGINEERING COMPANY THREE WAY ZONE VALVE PRIORITY DHW EP P 328 00 13 EPP SERIES INDIRECT WATER HEATERS WIRING LEGEND 7 FACTORY WIRING NEC CLASS FACTORY WIRING NEC CLASS II FIELD WIRING NEC CLASS FIELD WIRING NEC CLASS Installation and Service Manual J1 INSTALLED NOT INSTALLED JUMPER SETTING DETAI
12. L BLACK ZONE CONTROL t BOARD PLUG 1 o die suck 1 c GREEN Back 1 u 2 RELAY 3 dire WHITE PUMP 2 lt a WHITE TRANSFORMER ei ELI RED 36 PIC d 120 Vac 24 Vac Cl Geng 120 Voc Im ZONE 1 L1 ERAS OMM e ES EE O O WHITE A Sen S 8 8 2 S 8 2 z 2 amp 8 GROUND wo ae ae ae iT 23 11 28 01 L ON THE BOILER ON JHE LER Qo REI l l holy gg KN Fg N 1 RR RR RR YY RR NOTE L L VAL VALVE 4 NON PRIORITY TO ZONE 1 TANK AQUASTAT TH1 TANK ZONE VALVE ZONE VALVE 1 TANK DHW WIRING DIAGRAM FOR EP TANKS ZONE VAVES WITH ZCB NON PRIORITY DHW ALLIED ENGINEERING COMPANY EP W 001 00 WIRING LEGEND c FACTORY WIRING NEC CLASS FACTORY WIRING NEC cuss H FIELD WIRING NEC CLASS FIELD WIRING NEC CLASS Il OPTIONAL PUMP 1 vu BACK 120 Voc L2 see ee WHITE GROUND b e ee ON THE BOILER CONTROL PANEL NOTE PRIORITY TO ZONE 1 TANK AQUASTAT TH1 TANK ZONE VALVE ZONE VALVE 1 WIRING DIAGRAM FOR EP TANKS BLACK gt WHITE ve e e BLACK gel Ji INSTALLED NOT INSTALLED JUMPER SETTING DETAIL ZONE CONTROL BOARD PLUG 2 5 A FUSE TRANSFORMER 120 Vac 24 Vac BR 111 111
13. NG REQUIRED BY LOCAL CODES SHUT OFF DI ELECTRIC UNIONS MUST BE USED ON THE TANK CONNECTIONS TO VALVE PREVENT GALVANIC CORROSION 2 WAY ZONE PRIORITY VALVE BACKFLOW EXPANSION PREVENTER TANK PIPING SYSTEM FOR EP TANKS ALLIED ENGINEERING COMPANY RADIANT FLOOR OR HOT TUB POOL USING DOUBLE COIL TANK EP P 319 00 EPP SERIES INDIRECT WATER HEATERS Installation and Service Manual Multiple Water Heaters NOTES AT F n DRAN AE THIS DRAWING IS MEANT TO SHOW SYSTEM PIPING CONCEPT ONLY Y INSTALLER IS RESPONSIBLE FOR ALL EQUIPMENT AND DETAILING REQUIRED BY LOCAL CODES pla suo AIR EXPANSION TANK MUST BE USED IF A BACKFLOW PREVENTER CHECK VALVE Ne ONE 77777 VALVE ELIMINATOR IS INSTALLED ON DCW INLET DI ELECTRIC UNIONS MUST BE USED TO PREVENT GALVANIC CORROSION NI 255 packrlow EI EXPANSION PREVENTER TANK WATER FLL 1 I 4 gt COLD WATER IN PIPING SYSTEM FOR EP TANKS ALLIED ENGINEERING COMPANY MULTIPLE WATER HEATERS PIPED IN PARALLEL EP P 320 00 NOTES AVE TTA eech THIS DRAWING IS MEANT TO SHOW SYSTEM PIPING CONCEPT ONLY INSTALLER IS RESPONSIBLE FOR ALL EQUIPMENT AND DETAILING REQUIRED BY LOCAL CODES
14. SHOEGFE AR EXPANSION TANK MUST BE USED IF A BACKFLOW PREVENTER CHECK VALVE VALVE ELIMINATOR IS INSTALLED ON DCW INLET DLELECTRIC UNIONS MUST BE USED TO PREVENT GALVANIC CORROSION BACKFLOW EXPANSION PREVENTER TANK 4 COLD WATER IN PIPING SYSTEM FOR EP TANKS ALLIED ENGINEERING COMPANY MULTIPLE WATER HEATERS PIPED IN SERIES EP P 321 00 EPP SERIES INDIRECT WATER HEATERS Installation and Service Manual 23 DOMESTIC SIDE PLUMBING Connect domestic water in and domestic water out to the marked fittings on the water heater Use Teflon tape pipe dope or both on all threaded fittings Connect drain valve near the inlet connection so that the tank can be drained Shut off valves and dielectric unions must be used when installing your water tank to simplify future service requirements and prevent galvanic corrosion You must install an expansion tank of adequate capacity if a backflow preventer check valve or pressure reducing valve is installed on the cold water inlet Do not install any valve or restrictions between expansion tank and hot water tank inlet Improper piping of the expansion tank or backflow preventer can cause excessive pressure in the water heater which can cause severe personal injury death or substantial damage to property Actual service pressure should not exceed that of pressure stamped on the T amp P relief valve minus 25psi 24 T amp P RELIEF VALVE PLUMBING Install the T a
15. TES 2 CC 22 9 0 Ert 24 24
16. UST BE USED ON THE TANK CONNECTIONS TO VALVE VALVE VALVE PREVENT GALVANIC CORROSION BACKFLOW EXPANSION PREVENTER TANK FILTER TO DRAIN COLD WATER IN PIPING SYSTEM FOR EP TANKS ALLIED ENGINEERING COMPANY DOMESTIC PIPING USING THERMOSTATIC MIXING VALVE WITH RECIRCULATION LINE EP P 323 00 11 EPP SERIES INDIRECT WATER HEATERS Installation and Service Manual 3 0 WIRING DIAGRAMS Turn off all the electric power before any wiring or service All circuit breakers ahead of or related to the boiler and tank operation must be switched off Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation When installed the tank must be grounded in accordance with local codes or in the absence of local codes with the National Electrical Code ANSI NFPA 70 and or the CSA C22 1 Electrical Code All wiring is to be done in accordance with all applicable local and state provincial codes Wiring for the aquastat is to be connected through the junction box below the aquastat opening The aquastat is to be connected in series For line voltage connections over 30 volts wiring must be securely fastened at the junction box opening not provided HIGH VOLTAGE 120 VAC FIELD WIRING LOW VOLTAGE 24 VAC FIELD WIRING TANK SPACE HEATING SPACE HEATING AQUASTAT WI THERMOSTAT 3 23 gat 4 2 i I 1 r 1
17. cceccccececceccceccensceeeeeceserauceuseeeuseeseueesensensesensess 10 2 5 WATER HAMMIER iecit ei ee Gi e E eese tribe eit iens 10 3 0 WIRING DIAGRANSS nhanh hs nnn sas spa sus snp 12 4 0 STARTUP AND ADJUSTMENT 1 ener nennen nnne nh nn 17 4 1 PRE START UP CHEGKEIST tee oce dere oe eee e ee enne 17 4 2 STARTUPINSTRUGTIONS hua m bee Pese tive oc ett eu Sce ua mu e Chev ee 17 5 0 WATER ADJUSTMENT coe eroe ete co ooi U E gar ra nl Du ruens UR re repr a PEDE 18 5 1 GONITZROL AQUAS TA Routes tete yay see tet at eee 18 5 2 AQUASTAT TEMPERATURE E eas 18 5 3 TEMPERATURE ADJUSTMENT acc c cccccocsscossccsscsccscccccscccsccosccccvccccsseceuscosesccesecandencescosnsccseccueceseuss 19 6 0 MAINTENANCE amp SERVIGE U 19 6 1 GENERAL OPERATION cccccceccccecccccececcccecccaececcucececensececcecausensececeeeeaacecauceseusensesenseeneneenass 19 6 2 ANNIAISERVIG E mto et wre Pack amaya uka eed e etas 20 6 3 MONTHEY SERVICE moisi ett cete esL aol uie e bac sedo mti pos de dh 20 7 0 TROUBLESHOOTING GUIDE J U U U U u 21 8 0 NO
18. draining tank use caution as water will be hot Shut off power e Shut off domestic water supply to tank To relieve pressure in tank open a hot water faucet e Open drain valve Allow water to flow until it runs clear or empties e For chemical flushing remove the relief valve and apply the chemical flushing technique as per the manufacturer s instructions e Close drain valve e Open domestic water inlet shut off valve Close hot water faucet after flow is established e Resume power T amp P Relief Valve ZS Before operating T amp P relief valve make sure no person is near the T amp P relief valve discharging piping Hot discharge water can cause severe personal injury or substantial property damage Check T amp P relief valve is in accordance with manufacturer s instructions If short of such instructions perform the following move operating lever to open position for a few seconds and then move it back allowing it to snap closed If the relief valve continues to release water close cold water inlet to water heater immediately Follow Flushing the tank instructions to drain water and replace T amp P relief valve Anode Rod To prevent corrosion each hot water tank is equipped with an anode rod usually accessible from the top of the tank The anode dissolves slowly over a period of time sacrificing itself and preventing water ions from attacking the tank Replacement of a depleted anode rod can extend the life of your
19. e 25 WATER HAMMER Water hammer is a damaging pressure shock wave created when the flow of water is suddenly stopped or reduced possibly induced by fast closing faucet reducing valve or solenoid valve in a clothes dish washing machine This condition is commonly associated with hammering noises and vibrations however lack of noise does not assure that water hammer is not present Risers or air chambers must not be used To prevent damage to pipes and appliances 1 Install water hammer arrestors at all required locations and 2 adequately size pipes to ensure a maximum water velocity less than 5 ft s EPP SERIES INDIRECT WATER HEATERS Installation and Service Manual Domestic Side Piping Domestic piping with thermostatic mixing valve VACUUM NOTES MENER THIS DRAWING IS MEANT TO SHOW SYSTEM PIPING CONCEPT ONLY INSTALLER IS RESPONSIBLE FOR ALL EQUIPMENT AND DETAILING REQUIRED BY LOCAL CODES TA P RELIEF SHUT OFF E DHELECTRIC UNIONS MUST BE USED ON THE TANK CONNECTIONS TO PREVENT GALVANIC CORROSION BACKFLOW EXPANSION TANK PREVENTER RIETER TO DRAIN COLD WATER IN rt PIPING SYSTEM FOR EP TANKS ALLIED ENGINEERING COMPANY DOMESTIC PIPING WITH THERMOSTATIC MIXING VALVE EP P 322 00 VACUUM NOTES BREAKER THIS DRAWING IS MEANT TO SHOW SYSTEM PIPING CONCEPT ONLY INSTALLER IS RESPONSIBLE FOR ALL EQUIPMENT AND DETAILING MIXING REQUIRED BY LOCAL CODES T amp R RELIEF SHUT OFF DI ELECTRIC UNIONS M
20. ent room for the water heater to access all of the fittings easily We recommend a service clearance of 24 around plumbing connections The tank should be located in an area where leakage of the indirect water heater or connections will not result in damage to the area adjacent to the appliance or to lower floors of the structure When such locations cannot be avoided it is recommended that a suitable drain pan adequately drained connected to a drain be installed under the tank e This tank must be installed such that any electronic components are protected from water dripping spraying rain etc during appliance operation and service e Avoid heat loss and friction loss by locating the tank as close to the boiler as possible Further heat loss should be avoided by insulating the pipe e For the fastest delivery of hot water locate the water heater in a position central to the points of use Do not use or store gasoline or other flammable fuels or chemicals which have flammable vapors near the tank The vapors may be ignited by the heat or electronic components of the tank EPP SERIES INDIRECT WATER HEATERS Installation and Service Manual 1 4 OPERATING RESTRICTIONS Single wall heat exchangers must use a heat transfer medium such as water or other non toxic fluids having a toxicity rating of Class 1 as listed in Clinical Toxicology of Commercial Products current edition The pressure of the heat transfer medium must be limi
21. ges periodically this may be due to thermal expansion in a closed water supply system Contact the water supplier or local plumbing inspector on how to correct this situation Do not plug the temperature and pressure relief valve Hydrogen Sulfide gas can be produced in a hot water system that has not been used for a long period of time generally two weeks or more Hydrogen Sulfide gas is extremely flammable To prevent the possibility of injury under these conditions we recommend the hot water faucet to be open for several minutes at the kitchen sink before you use any electrical appliance which is connected to the hot water system If hydrogen is present there will probably be an unusual sound such as air escaping through the pipe as the hot water begins to flow There should be no smoking or open flame near the faucet at the time it is opened Verify proper operation after servicing EPP SERIES INDIRECT WATER HEATERS Installation and Service Manual 6 2 ANNUAL SERVICE The owner or user should have a qualified heating technician perform annual service as follows 6 3 1 Water Piping Check all domestic water and boiler water piping for signs of leakage at joints valves unions and other fittings Controls and Valves Check function of controls and valves as per the controlvalve manufacturer s instructions If the circulator is oil lubricated follow the instructions on the circulator to oil it Flushing the tank e When
22. he water heater and can be prioritized by correct use of the control valve Ensure that the circulator is sized correctly to allow the boiler water to flow at the correct rate Zone Valve System Run the same as a standard heating zone except one zone is piped to the water heater and can be prioritized with correct use of the zone valves Ensure that the circulator is sized correctly to allow the boiler water to flow at the correct rate Do not use a zone valve less than 1 inch diameter and Cy 8 3 way Zone Valve System For prioritizing your water heater a 3 way zone valve can be installed into your system This system overrides all other calls for heat when there is a demand from the water heater aquastat All the boiler water is then diverted to the water heater There are three ports on a 3 way valve a common port a normally closed port and a normally open port The common port is connected to the boiler side the normally open port connected to the heating zone and the normally closed is connected to the water heater coil The boiler water flows through the heating zone until the water heater aquastat demands more heat The zone valve is then activated and the boiler water is diverted to the water heater once the requested water temperature is achieved the aquastat will shut off power to the zone valve and the boiler water will be diverted back to the heating zone EPP SERIES INDIRECT WATER HEATERS Installation and Service Manua
23. hot water tank and should be checked annually The anode rod should be replaced when the anode core becomes visible at any point along the rod Before attempting to remove the anode shut the cold water supply and drain enough water to empty the piping system Hot discharge water can cause severe personal injury or substantial property damage Flexible link rods anodes may be used if clearance from the top of the tank to the ceiling does not permit standard lengths Contact your local hardware store or the manufacturer for replacement anode rods Failure to maintain an anode may result in premature failure of the tank and voids warranty Anode rod inspection may need to be performed more frequently in areas with low pH value as it will cause the anode to deplete more rapialy Teflon Tape reduces the effectiveness of the Magnesium Anode by acting as an insulator An electrically conductive sealant should be used on the anode threads MONTHLY SERVICE Visual Check Visually check joints valves and other fittings for leaks Call a qualified service technician to repair any leaks found These instructions are for general guidance only please contact a technician or plumber for required local codes and standard procedures 20 EPP SERIES INDIRECT WATER HEATERS Installation and Service Manual 7 0 Troubleshooting Guide Problem No Hot Water Insufficient Hot Water Slow Hot Water Recovery Water Too Hot Discharge From
24. l 2 2 INSTALLATION DIAGRAMS Sample Schematics Boiler Side Piping pla Sees SHUT OFF VALVE RELIEF VALVE NI RU packrlow EXPANSION PREVENTER TANK PIPING SYSTEM FOR EP TANKS DEDICATED SINGLE BOILER WITH SINGLE COIL TANK NOTES THIS DRAWING IS MEANT TO SHOW SYSTEM PIPING CONCEPT ONLY INSTALLER IS RESPONSIBLE FOR ALL EQUIPMENT AND DETAILING REQUIRED BY LOCAL CODES DI ELECTRIC UNIONS MUST BE USED ON THE TANK CONNECTIONS TO PREVENT GALVANIC CORROSION ALLIED ENGINEERING COMPANY EP P 314 00 fo UNION Den BRAN g RORE UAE VALVE Vv suror _____ AR we pa 3 WAY ZONE N BEEN BACKFLOW EI EXPANSION _____ PRIORITY PREVENTER TANK VALVE NOTES THIS DRAWING IS MEANT TO SHOW SYSTEM PIPING CONCEPT ONLY INSTALLER IS RESPONSIBLE FOR ALL EQUIPMENT AND DETAILING REQUIRED BY LOCAL CODES DI ELECTRIC UNIONS MUST BE USED ON THE TANK CONNECTIONS TO PREVENT GALVANIC CORROSION PIPING SYSTEM FOR EP TANKS RADIANT FLOOR BASEBOARD WITH 3 PORT ZONE VALVE DOMESTIC PRIORITY ALLIED ENGINEERING COMPANY EP P 315 00 EPP SERIES INDIRECT WATER HEATERS Installation and Service Manual BACKFLOW PREVENTER RELIEF VALVE SHUT OFF VALVE 2 WAY ZONE PRIORITY VALVE EXPANSION TANK PIPING SYSTEM FOR EP TANKS RADIANT FLOOR BASEBOARD WTH 2 PORT ZONE VALVE DOMESTIC PRIORITY RELIEF
25. mit the potential for legionella pneumophila growth Contact your local health authority for more information 5 1 CONTROL AQUASTAT Insert the control into the factory installed stainless steel well and secure it to the well by using the screw on the aquastat body Thermal paste is recommended but not required The water temperature and the setting of the aquastat will be similar most of the time but due to unusual usage patterns the outlet water temperature may rise significantly above the setting of the aquastat To control this fluctuating temperature a thermostatic mixing valve tempering valve should be installed 5 2 AQUASTAT TEMPERATURE e Use the aquastat to control the maximum water temperature in the tank Its differential is fixed at 5 F 3 C Its maximum setting is 160 F 71 C e Household water usage patterns will affect water temperature at any faucet or shower Always check temperature at every point after adjusting aquastat e When hot water is used in repeated small quantities the upper layer of water in tank can be much hotter than lower layers When adjusting the aquastat be sure boiler limit control is set a minimum 20 F 11 higher However in no case should boiler limit control be set above 210 F 99 EPP SERIES INDIRECT WATER HEATERS Installation and Service Manual 5 3 TEMPERATURE ADJUSTMENT Allow the water heater to operate several heat up cycles and check the water temperature at the faucet to
26. mp P relief valve directly into the 34 tapping located near the top of the tank so that the temperature sensing element is immersed in the water within the top 6 inches of the tank No valve reducing coupling or other restriction is to be placed between the relief valve and the tank connection No valve reducing coupling pipe plug pipe cap or other restriction is to be placed in the discharge piping Improper placement or piping of the T amp P relief valve can cause severe personal injury death or substantial property damage The discharge line shall be installed to allow the complete drainage of both the valve and the line It shall be independently supported or arranged so as to avoid undue stress on the valve The discharge line must be installed to allow complete drainage of both the valve and line Do not pipe in any area where freezing may occur The termination of the T amp P relief valve discharge line shall be downward and not directly connected to a sewer line The outlet of the discharge line shall terminate in the vicinity of a point of drainage within 6 of the floor to eliminate potential risk of scalding Temperature and pressure settings of the T amp P relief valve are factory set and are not adjustable DANGER Do not plug T amp P relief valve or discharge piping Plugging T amp P relief valve or discharge piping can cause excessive pressure in water heater resulting in severe personal injury death or substantial property damag
27. nt safe and proper operation 1 2 INSTALLATION CODES AND REQUIREMENTS All applicable national provincial state and local codes laws regulations and ordinances must be followed They expand on and take precedence over any recommendations in this booklet Authorities having jurisdiction shall be consulted before installations are made If an external electrical source is utilized the hot water tank when installed must be electrically grounded in accordance with local codes or in the absence of local codes with the National Electrical Code ANSI NFPA 70 current edition and or the Canadian Electrical Code CSA C22 1 Part 1 current edition If there is any conflict in the above requirements the more stringent requirement applies The installation and service must also conform to the additional requirements in this manual If there is any conflict with a requirement in this manual and a code requirement the code requirement must be followed 1 3 LOCATION e This tank should not be placed where freezing might occur and is not to be installed outdoors e This tank is designed for vertical installation Install the tank on an area that is stable flat level and capable of supporting the weight of the tank when filled with water Failure to support and stabilize the water heater could result in severe personal injury death or substantial water damage e Although minimal clearance is required for this tank ensure that there is suffici
28. ted to a maximum of 150psi by an approved pressure relief valve Maximum working pressure of the tank is 150psi 1 5 WATER QUALITY Always use good quality water to prolong the life of the tank Water that is safe to drink and even city water is not necessarily good quality water for the tank The use of filters can prevent corrosion and reduce sediments inside the tank Water hardness pH and chlorides must be controlled to normal levels e PH levels must be between 6 0 and 8 0 and dissolved chlorides below 100ppm If you are unsure use a water softening system or consult a qualified water treatment expert NOTE All improper use as detailed above could void the warranty of the tank EPP SERIES INDIRECT WATER HEATERS Installation and Service Manual 2 0 PIPING AND PLUMBING 2 1 BOILER SIDE PLUMBING Connect boiler out hot supply piping to the fitting marked boiler in on the water tank The boiler out fitting on the tank should be piped to the boiler return Use Teflon tape pipe dope or both on all threaded fittings When installing the pump make sure that the direction arrow is pointing in the same direction as the flow The use of shut off valves and dielectric unions are recommended when installing your water tank to simplify future service requirements To prevent a back flow through the water heater when heating a radiant system a check valve or back flow preventer must be installed The heat output
29. tion and Service Manual 5 0 WATER ADJUSTMENT Water Temperatures over 125 F 52 can cause severe burns instantly or death from scalds Feel water before bathing and showering Homes that have small children elderly and disabled persons may wish to lower the water heater setting to 120 F 49 C to prevent potential scalding Below is a table showing the approximate time it takes to have a scalding accident for different temperatures of hot water Water Temperature Length of Time to Cause Scalding DANGER 125 F 52 C 1 1 2 to 2 minutes 130 F 54 C about 30 seconds 135 F 57 C about 10 seconds 140 F 60 C less than 5 seconds 145 F 63 C less than 3 seconds 150 F 66 C about 1 1 2 seconds Maximum boiler water temperature is 210 F You should install a mixing valve or tempering valve on the domestic hot water supply and set to 120 F 49 C Valves for reducing point of use temperature by mixing cold and hot water are available Consult a licensed plumber or local plumbing authority WENA Studies show that dangerous bacteria can form in domestic water distributions systems if a minimum water temperature is not maintained For example legionella pneumophila can form in hot water maintained at 115 F 46 C or lower We recommend a domestic water temperature not lower than 122 F 50 at faucets and a tank temperature not lower than 140 F 60 C to li
30. verify proper operation If the water at the faucet is hotter than needed 1 Adjust the aquastat to a lower temperature setting 2 Draw sufficient water or allow the water to sit until another heat up cycle is initiated 3 Wait until the heat up cycle is completed 4 Recheck the water temperature at the faucet If the water at the faucet is colder than needed 1 Adjust the aquastat to a higher temperature setting 2 If a heat up cycle begins wait until the heat up cycle is completed and recheck the water temperature at the faucet 3 If a heat up does not begin draw sufficient water or allow the water to sit until a heat up cycle is initiated Wait until the heat up cycle is completed Recheck the water temperature at the faucet 6 0 MAINTENANCE amp SERVICE The EPP Series Indirect Hot Water Tank has been designed to provide years of trouble free performance in normal installations and requires minimal routine maintenance to ensure a reliable and safe supply of hot water 6 1 GENERAL OPERATION YNA Before operating the T amp P relief valve make sure no person is near the T amp P relief valve discharging piping DANGER Do not plug T amp P relief valve or discharge piping Plugging T amp P relief valve or discharge piping can cause excessive pressure in water heater resulting in severe personal injury death or substantial property damage If the temperature and pressure relief valve on the appliance dischar
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