installation and service manual epj series – indirect water heaters
Contents
1. J U I I U u 22 SECTION 8 WARRANTY REGISTRATION I I I UU 23 SECTIONS NOTES uai inopes be CR Pe MD Ded ob Say Saa ln 25 SEGTION TO INDEX Pata 28 282. Sil ON THE BOILER t 1 _1_ 4 ON THE EN Bib Hl EJ IO IO MIO 1 1 1 1 1 1 1 1 BLACK 1 1 NON PRIORITY TO ZONE 1 120 H a bee deese 1 TANK AQUASTAT 1 L2 ATE TANK PUMP ZONE PUMP 1 WIRING DIAGRAM FOR EP TANKS ALLIED ENGINEERING COMPANY PUMPS WITH ZCB NON PRIORITY DHW 005 01 WIRING LEGEND FACTORY WIRING NEC CLASS FACTORY WIRING NEC CLASS II gt gt FIELD WIRING NEC CLASS FIELD WIRING NEC CLASS Il NOT INSTALLED JUMPER SETTING DETAIL ZONE CONTROL BACK BOARD PLUG OPTIONAL PUMP 1 were BLACK lt a GREEN Lu e RELAY 5 WHITE TRANSFORMER lt e RED 120 24 Io N e OBOILER e 2 OZONE 1 La ly E ZONE 3 120 VGC fior ara dey st L2 WHITE s LIGTLOGO GROUND 9 T d 1 79 5 E M 79 o el ON THE BOILER G I TA at t P CONTROL PANEL Ti pa hd ud 4 EnS i KI Per t li Bi t NOTE 1 1 l PRIORITY 70 1 1 O TANK AQUASTAT TH1 1 4 1 i TANK PUMP ZONE PUMP 1 qst BLACK 1 ME s 1 1 1 4 1 1 WHITE WIRING DIAGRAM FOR TANKS PUMPS WITH ZCB PRIORITY DHW ALLIED ENGINEERING COMPANY 004 01
3. INSTALLATION AND SERVICE MANUAL EPJ SERIES INDIRECT WATER HEATERS FOR MODELS EPJ 40 AND EPJ 56 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 Allied Engineering Company Division of E Z Rect Manufacturing Ltd Manufacturers of Gas and Electric Boilers Heat Exchangers Electric Boosters Indirect Tanks 94 Riverside Drive North Vancouver B C V7H 2M6 e Telephone 604 929 1214 www alliedboilers com Branches Calgary Edmonton e Toronto Denver PN11393615 SERIES INDIRECT WATER HEATERS Installation and Service Manual TECHNICAL SPECIFICATIONS AND DIMENSIONS SPECIFICATIONS Storage Standby Loss Standby Loss R value Shipping Capacity Btu h F hr ft h F Btu Weight OPERATING LIMITS Maximum Tank Temp 150 F Maximum Coil Temp 210 Maximum Pressure 150 psi MATERIALS OF CONSTRUCTION Tank AISI 444 Stainless Steel Coil AISI 444 Stainless Steel Insulation EPS Foam Insulation 2 inch thickness Jacket Polypropylene Notes Each tank is Pickled and Passivated and Factory Pressure Tested to 300 psi RECOVERY Based on Flow Rate of 10 GPM 1 10 Min 1 Hour Continuous Thermal Heat S cn Delivery Delivery
4. a it it Li l 4 RR RR reve RE ES RE NOTE PRIORITY TO ZONE 1 TANK AQUASTAT TH1 TANK ZONE VALVE ZONE VALVE 1 Demem WIRING DIAGRAM FOR TANKS ALLIED ENGINEERING COMPANY ZONE VAVES WITH ZCB PRIORITY DHW 002 01 14 SERIES INDIRECT WATER HEATERS Installation and Service Manual WIRING LEGEND FACTORY WIRING NEC CLASS FACTORY WIRING NEC CLASS Il FIELD WIRING NEC CLASS FIELD WIRING NEC CLASS II Jt NOT INSTALLED INSTALLED JUMPER SEITING DETAIL ZONE CONTROL BOARD PLUG OPTIONAL PUMP 1J WHITE e BLACK CREEN _ RELAY ex WHITE i TRANSFORMER lt RED id 120 Vac 24 Vac 2 o J1 E e 2 OZONE 1 Esse Boe 2 ZONE 3 120 12 OZONE 4 12 WHITE LE i A EE AE GROUND U PEP S qp w POMP 2 1 POMPE L1
5. HIGH VOLTAGE 120 VAC FIELD WIRING LOW VOLTAGE 24 VAC FIELD WIRING TANK SPACE HEATING SPACE HEATING AQUASTAT THERMOSTAT THERMOSTAT 1 1 L 1 MEE Pd MEE FUSE Sica i i 1 ee amp 2T 120 24 l I NC ee T lt paru ge I 1 1 1 1 1 n I 3 WAY ZONE t os VALVE T T T 1 1 1 1 1 1 xo a JT 2 24 TO BOILER 24 VAC THERMOSTAT I CONNECTIONS WIRING DIAGRAM FOR EP TANKS THREE WAY ZONE VALVE PRIORITY DHW ALLIED ENGINEERING COMPANY 328 01 SERIES INDIRECT WATER HEATERS Installation and Service Manual t WIRING LEGEND FACTORY WIRING NEC CLASS FACTORY WIRING NEC CLASS FIELD WIRING NEC CLASS FIELD WIRING NEC CLASS I J1 NOT NSTALLED BLACK JUMPER SETTIN
6. 15 SERIES INDIRECT WATER HEATERS Installation and Service Manual WIRING LEGEND FACTORY WIRING NEC CLASS FACTORY WIRING NEC CLASS Il lt lt lt FIELD WIRING NEC CLASS FIELD WIRING NEC CLASS II JUMPER J1 AND J2 INSTALLED J1 INSTALLED INSTALLED 2 JUMPER SETTING DETAIL BLACK ZONE CONTROL OPTIONAL BOARD PLUG WIE ex m BLACK 9 GREEN Back 1 1 1 RELAY WHITE Ba y WHITE by TRANSFORMER 3 PC J1 120 Vac 24 Vac COBOILER 120 Vac J2 OZONE 1 L2 Wa e I e 2 Q OZONE 4 GROUND ry ARE o o ss masu ON THE BOILER 5 06 CONTROL PANEL T PRIORITY ZONE 1 TANK AQUASTAT TH1 TANK PUMP ZONE PUMP 2 L TANK DHW WIRING DIAGRAM FOR FP TANKS DEDICATED SINGLE BOILER WITH SINGLE TANK ALLIED ENGINEERING COMPANY EP W 005 01 16 SERIES INDIRECT WATER HEATERS Installation and Service Manual Startup and Adjustment Section 4 ANAA Before filling the tank make sure that the T amp P relief valve is installed and that the unit is properly grounded Never use tank until it is filled with water and
7. SERIES INDIRECT WATER HEATERS Installation and Service Manual 2 4 T amp P RELIEF VALVE PLUMBING WEM T amp P temperature and pressure relief valve must be installed to protect the tank from excessive temperature and pressure Temperature and pressure settings of the T amp P relief valve are factory set and are not adjustable The T amp P valve must be of sized capacity to handle the maximum heat input to the indirect water tank and not greater than the operating restrictions stated on the rating plate of the indirect water heater and in this manual Furthermore the service pressure should be at least 25 psi less the setting stamped on the T amp P relief valve Install the T amp P relief valve directly into a tee on the hot water outlet of the tank so that the temperature sensing element is immersed in the water at the top of the tank No valve reducing coupling or other restriction is to be placed between the T amp P 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 dra
8. 24 BOILER SIDE PLUMBING nn 6 22 5 toa anlar task code ibd 7 23 DOMESTIC SIDE PLUMBING I 10 24 T amp P RELIEF VALVE PLUMBING I 11 25 WATERHAMMEFER a a 11 SECTION 3 WIRING DIAGRANMS III U u u 12 SECTION 4 STARTUP AND ADJUSTMENT I I U U u 17 AD PRE START UP CHECKLIST eie nent os bna 17 42 STARTUPINSTRUCTIONS I ero re bra de ix rare edo edente aget 17 SECTION 5 WATER I I U 18 A 18 5 22 AQUASTAT TEMPERATURE lb addc creta eden 18 53 TEMPERATURE ADJUSTMENT 19 SECTION 6 SERVICE AND MAINTENANCE II I I u 20 GENERALOGPERATION ay unan nl una uay 20 62 ELECTRONIC ANODE AS ru 20 6 GANNBAISSEBVIGE area men pi d MN EE 21 Gad MONTHECSEBVIGE2 srt E Er M Ea ad EP ERI EE 21 SECTION 7 TROUBLESHOOTING
9. Water Adjustment Section 5 Water Temperatures over 125 F 52 C 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 A DANGER 1 1 2 to 2 minutes about 30 seconds 52 C 54 C i 135 F 57 C about 10 seconds 8 0 140 60 less than 5 seconds 63 3 66 C less than 3 seconds about 1 seconds lon Maximum coil boiler water temperature is 210 F A thermostatic mixing valve or tempering valve should be installed on the domestic hot water supply and set to a maximum of 120 F 49 Valves for reducing point of use temperature by mixing cold and hot water are available Consult a licensed plumber or local plumbing authority 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 50 at faucets a tank temperature not lower than 140 F 60 to limit the
10. M NE ZONE ZONE M AE i m VALVE E VALVE L 1 1 1 1 DEN Er 1 1 TO BOILER 24 VAC 1 1 1 1 CONNECTIONS 2 WIRING DIAGRAM FOR TANKS ALLIED ENGINEERING COMPANY ZONE VALVE NON PRIORITY DHW 326 00 12 EPJ SERIES INDIRECT WATER HEATERS Installation and Service Manual HIGH VOLTAGE 120 VAC FIELD WIRING LOW VOLTAGE 24 VAC FIELD WIRING ON OFF EUSE SWITCH H 120 N SPACE HEATING SPACE HEATING AQUASTAT THERMOSTAT THERMOSTAT ZONE 2 1 1 P 1 1 1 1 s zs J A T 4 1 se 1 4 i 24 I NORMALLY CLOSED RELAY 1 apts fP p s I ZONE ZONE VALVE tT VALVE tT mi VALVE I I 1 1 1 1 1 Lo 1 4 4 4 1 1 1 m CONNECTIONS 3 WIRING DIAGRAM FOR TANKS ALLIED ENGINEERING COMPANY ZONE VALVE PRIORITY DHW EPSP 32 00
11. SYSTEM PIPING CONCEPT ONLY INSTALLER IS RESPONSIBLE FOR ALL EQUIPMENT AND DETAILING REQUIRED BY LOCAL CODES AIR EXPANSION TANK MUST BE USED IF A BACKFLOW PREVENTER CHECK VALVE s PUMP TTT VALVE 7 ELIMINATOR IS INSTALLED ON DCW INLET BACKFLOW J _____ EXPANSION N PREVENTER TANK pa ZONE YALE DHW OUT Cold Water Fil COLD WATER IN SEE DHW SIDE CONNECTIONS SYSTEM FOR EPJ TANKS MULTIPLE WATER HEATERS PIPED IN SERIES ALLIED ENGINEERING COMPANY 321 03 SERIES INDIRECT WATER HEATERS Installation and Service Manual 2 3 DOMESTIC SIDE PLUMBING Connect domestic cold water in to the fitting marked drain cold water in and domestic hot water out to the fitting marked hot water outlet Use Teflon tape pipe dope or both on all threaded fittings Connect a drain valve near the cold water inlet connection so that the tank can be drained Connect a control aquastat and stainless steel thermowell to the coupling marked sensor well Shut off valves and brass or dielectric unions must be used when installing your water tank to simplify future service requirements and prevent galvanic corrosion If a backflow preventer check valve or pressure reducing valve is installed upstream of the tank on the cold water inlet a potable water expa
12. a maximum water velocity less than 5 ft s 11 SERIES INDIRECT WATER HEATERS Installation and Service Manual Wiring Diagrams Section 3 Turn off all electric power before attempting 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 They expand on and take precedence over any recommendations in this manual Wiring for the aquastat is to be connected through the junction box below the aquastat opening The aquastat is to be connected in parallel with the zone valve motor For line voltage connections over 30 volts wiring must be securely fastened at the junction box opening not provided M HIGH VOLTAGE 120 VAC FIELD WIRING LOW VOLTAGE 24 VAC FIELD WIRING TANK SPACE HEATING SPACE HEATING AQUASTAT THERMOSTAT THERMOSTAT 1 1 1 M a d o 120 24 VAC pe rr IE ps 24 1 EM
13. 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 of adequate capacity be installed under the tank Failure to comply with the above could result in severe personal injury death or substantial property damage 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 fastest delivery of hot water locate the water heater 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 SERIES INDIRECT WATER HEATERS Installation and Service Manual 14 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
14. Delivery Input Source oer emp 9 135 F 9 115 Required Friction 2 US Gal US Gal US GPH Btu h ft w c 200 206 129 000 EPJ 40 SC 190 190 117 000 180 174 105 000 200 222 129 000 EPJ 56 SC 190 206 117 000 180 190 105 000 Note Ratings are based upon 45 F cold water inlet temperature SERIES INDIRECT WATER HEATERS Installation and Service Manual B D Hot Water Inlet from Outlet to Cold Water Outlet Boiler Boiler Inlet Drain Notes 1 T amp P Relief valve connection not shown is at Dimension height and offset 30 counterclockwise 2 Aquastat sensor well and drain valve supplied as an option 3 Dimensions and Specifications subject to change without notice SERIES INDIRECT WATER HEATERS Installation and Service Manual Pre Installation Section 1 11 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 prevent safe and proper operation 1 2 INSTALLATION CODES AND REQUIREMENTS All applicable national provincial state and loca
15. G DETAIL La aa e e ZONE CONTROL OPTIONAL BOARD PLUG PUMP 1 QUEE iei BLACK a UD EE 9 WHITE RELAY 8 wl lt WHITE TRANSFORMER z Be xS IPC un 120 Vac 24 Vac S Osor 120 Vac Ozone 1 DES e Ozone 4 S au s ae s s GROUND a a a 99999 tq 1111 tt 2 t 1 ON THE SOLER O E CONTROL PANEL I Lord s c ledig Epp eese eb pue ETE Ta YY RR YY RR YY RR YY RR BE ES ES E NON PRIORITY TO ZONE 1 TANK AQUASTAT 1 TANK ZONE VALVE ZONE VALVE 1 TANK DHW WIRING DIAGRAM FOR EP TANKS ALLIED ENGINEERING COMPANY ZONE VAVES WITH ZCB NON PRIORITY DHW 001 01 WIRING LEGEND FACTORY WIRING NEC CLASS FACTORY WIRING NEC CLASS II FELD WIRING NEC CLASS I FIELD WIRING NEC CLASS II NOT NSTALLED JUMPER SETTING DETAIL ZONE CONTROL OPTIONAL BOARD PLUG PUMP 1 3 I ELAY 5 2 RED TRANSFORMER PIC ut 120 Vac 24 Vac of 2 m 2 OZONE 1 6 gt o 29 112 Ozone 4 GROUND a a x x 2 ZONE 2 _ 2 ZONE 5 ZONE ON HE BOER Lt CONTROL PANEL a Ee TS 7 opel os Mr al ore UE N I EINE EN r
16. L CODES 723 PIPING SYSTEM FOR EPJ TANKS RADIANT FLOOR BASEBOARD WITH 3 PORT ZONE VALVE DOMESTIC PRIORITY ALLIED ENGINEERING COMPANY 315 01 7 SERIES INDIRECT WATER HEATERS Installa Sample Schematics Boiler Side Pi tion and Service Manual ping cont d UNION 4 RELIEF VALVE SHUTOFF _____ AIR PUMP pla porc VALVE ELIMINATOR N sackrlow CD _____ EXPANSION PREVENTER TANK VALVE Cold Water Fill Ld NOTES THIS DRAWING IS MEANT TO SHOW SYSTEM PIPING CONCEPT ONLY INSTALLER IS RESPONSIBLE FOR ALL EQUIPMENT AND DETAILING REQUIRED BY LOCAL CODES PIPING SYSTEM FOR EPJ TANKS RADIANT FLOOR BASEBOARD WITH 2 PORT ZONE VALVE DOMESTIC PRIORITY ALLIED ENGINEERING COMPANY 316 01 UNION DRAN ea RELIEF VALVE eee PUMP pla SHUTOFF a ELIMINATOR N BACKFLOW _ _ ____ EXPANSION PREVENTER TANK Cold Wate Fill NOTES THIS DRAWING IS MEANT TO SHOW SYSTEM PIPING CONCEPT ONLY INSTALLER IS RESPONSIBLE FOR AL
17. L EQUIPMENT AND DETAILING REQUIRED BY LOCAL CODES 1 PIPING SYSTEM FOR EPJ TANKS ALLIED ENGINEERING COMPANY RADIANT FLOOR BASEBOARD USING CIRCULATOR AND DOMESTIC HOT WATER PRIORITY 317 01 Multiple Water Heaters EPJ SERIES INDIRECT WATER HEATERS Installation and Service Manual de ds RELIEF VALVE NOTES DRAIN 2 e THIS DRAWING IS MEANT SHOW SYSTEM PIPING CONCEPT ONLY INSTALLER IS RESPONSIBLE FOR ALL EQUIPMENT AND DETAILING REQUIRED BY LOCAL CODES AIR EXPANSION TANK MUST BE USED IF A BACKFLOW PREVENTER CHECK VALVE PUMP 7707777 VALVE 7777777 ELIMINATOR IS INSTALLED ON DCW INLET saves The rl ZONE VALVE DHW OUT s lt C lt v Cold Water 2 L gt gt E gt 6 6 6 5 IN c en COLD WATER IN Cl SIDE CONNECTIONS PIPING SYSTEM FOR EPJ TANKS ALLIED ENGINEERING COMPANY MULTIPLE WATER HEATERS PIPED IN PARALLEL 320 03 TE P REER DRAIN THIS DRAWING IS MEANT TO SHOW
18. PERATURE ADJUSTMENT Allow the water heater to operate several heat up cycles and check the water temperature at the faucet to verify proper operation e If the water at the faucet is hotter than needed 1 Adjust the aquastat to a lower temperature setting or thermostatic mixing valve if used 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 e If the water at the faucet is colder than needed 1 Adjust the aquastat to a higher temperature setting 2 f 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 19 SERIES INDIRECT WATER HEATERS Installation and Service Manual Service and Maintenance Section 6 The EPJ 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 6 2 GENERAL OPERATION Before operating the T amp P relief valve make sure no person is near the T amp P relief valve discharge piping Do not plug T amp P relief valve o
19. antie 23 SERIES INDIRECT WATER HEATERS Installation and Service Manual Soft STAMP 94 RIVERSIDE DRIVE l l l ALLIED ENGINEERING COMPANY l NORTH VANCOUVER V7H 2 6 L Li mmm pam mmm w e i mmm 24 SERIES INDIRECT WATER HEATERS Installation and Service Manual NOTES Section 9 25 SERIES INDIRECT WATER HEATERS Installation and Service Manual NOTES 26 SERIES INDIRECT WATER HEATERS Installation and Service Manual NOTES 27 SERIES INDIRECT WATER HEATERS Installation and Service Manual Index Section 10 Section Page DIMENSIONS AND SPECIFICATIONS 2 SECTION 1 PRE INSTALLATION 4 AAS RECEIVING Ming Lun 4 12 INSTALLATION CODES AND REQUIREMENTS eene ettet re 4 gine P PN RE 4 14 OPERATING 5 6 0 9 5 15 5 SECTION 2 PIPING AND 0 2000000101 I 6
20. connected to the domestic water piping and boiler piping 41 PRE START UP CHECKLIST T amp P 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 Boiler supply and return piping is correctly connected from boiler to tank Domestic and boiler water systems are set at the correct operating pressure D Do 0 All wiring is installed correctly no exposed high voltage wiring is present and the unit is properly grounded 4 2 STARTUP INSTRUCTIONS Make sure all electrical power is OFF Close the drain valve on tank Open domestic water supply valve Open the closest hot water faucet to vent air from the system Close faucet when there is a constant flow of water For boiler side piping follow boiler instructions to purge air DIE gr eR rm The tank domestic water piping and boiler water piping should be completely filled with water and all air purged from both domestic and boiler water systems 8 Setaquastat on water heater 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 17 SERIES INDIRECT WATER HEATERS Installation and Service Manual
21. current edition The pressure of the heat transfer medium must be limited to a maximum of 150 psi by an approved pressure relief valve Maximum tank temperature 150 F e Maximum coil temperature 210 F e Maximum working pressure 150 psi 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 water treatment and filters can prevent corrosion and reduce sediment in the tank Water hardness pH and chlorides must be controlled to normal levels e PH levels must be between 6 0 and 8 0 e Chlorine chlorides and aggressive sulfates concentrations must be below 100 parts per million 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 SERIES INDIRECT WATER HEATERS Installation and Service Manual Piping and Plumbing Section 2 2 1 BOILER SIDE PLUMBING Connect boiler out hot supply piping to the fitting marked boiler water in on the water tank The boiler water 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 brass or dielectric union
22. erated corrosion The Electronic Anode should be installed in the top of the tank using the factory supplied kit Please contact the factory for details Follow the anode manufacturers instructions regarding installation and inspection to ensure continuous and proper operation The inspection should be performed annually but may need to be more frequent in areas with water having low pH values or high hardness 20 SERIES INDIRECT WATER HEATERS Installation and Service Manual 6 3 ANNUAL SERVICE The owner or user should have a qualified heating technician perform annual service as follows 1 Water Piping Check all domestic water and boiler water piping for signs of leakage at joints valves unions and other fittings 2 Controls and Valves Check function of controls and valves as per the control valve manufacturer s instructions If the circulator is oil lubricated follow the instructions on the circulator to oil it 3 Flushing the tank e When draining tank use caution as water will be hot e Shut off power e Shut off domestic water supply to tank To relieve pressure in tank open a hot water faucet Open drain valve Allow water to flow until it runs clear or empties For chemical flushing remove the T amp P relief valve and apply the chemical flushing technique as per the manufacturer s instructions Replace T amp P relief valve after treatment Close drain valve e Open domestic water inlet
23. inage 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 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 Also the T amp P valve may discharge pressurized hot water which can turn into steam Steam exiting the discharge outlet can explosively expand in any direction Always maintain a safe distance from the discharge pipe outlet in order to avoid potential contact with exiting hot water or steam 2 5 WATER HAMMER Water hammer is a damaging pressure shock wave created when the flow of water is suddenly stopped or reduced possibly induced by a 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 of adequate size at all required locations and 2 adequately size pipes to ensure
24. l 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 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 MAGNIN Failure to support and stabilize the water heater could result in severe personal injury death or substantial property damage e Although minimal clearance is required for this tank ensure that there is sufficient room around the tank to access all of the fittings easily We recommend a service clearance of 24 around the
25. lator Zone valve not operating Check wiring and power supply open manually to check Replace zone valve Boiler not operating Insufficient Hot Water Temperature setting too low Boiler control too low Check wiring Check disconnect switch Check fuse or circuit breaker Check wiring and power supply Adjust aquastat or tempering valve 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 Slow Hot Water Undersized boiler with no priority to Recovery 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 Water Too Hot 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 Tempering mixing valve Discharge From T amp P Inlet cold water pressure too high Read valve instructions or consult with manufacturer Install pressure reducing valve Relief Valve Excessive water pressu
26. nsion tank of adequate capacity must be installed Do not install any valve or restrictions between the expansion tank and the hot water tank Improper piping of the expansion tank or backflow preventer could cause excessive pressure in the hot water tank and could result in hot water tank failure and substantial damage to property Actual operating temperature and pressure should not exceed that of operating restrictions stated on the rating plate of the indirect water heater and in this manual A T amp P relief valve must be installed Domestic Side Piping Domestic piping with optional re circ and thermostatic mixing valve NOTES THIS DRAWING IS MEANT TO SHOW SYSTEM PIPING CONCEPT ONLY INSTALLER IS RESPONSIBLE FOR ALL EQUIPMENT AND DETAILING _ THERMOSTATIC Joss DRAN T amp PRELIEF MIXING VALVE VALVE VALVE REQUIRED BY LOCAL CODES _ _ _ BRONZE OR pla SHUT OFF STAINLESS PUMP TO HI TEMP FIXTURES _ _ _ POTABLE WATER BACKFLOW EXPANSION TANK ae s PREVENTER Y FIXTURES RETURN VALVE p I OPTIONAL r RE CIRC FROM FIXTURES FROM BOILER BYPASS VALVE a uma ama DOMESTIC COLD WATER TO BOILER L j 119 SYSTEM FOR EPJ TANKS ALLIED ENGINEERING COMPANY DOMESTIC WATER CONNECTIONS 330 01 10
27. potential for legionella pneumophila growth Contact your local health authority for more information 51 CONTROL AQUASTAT A control aquastat and stainless steel thermowell must be installed in order to control the maximum temperature of the tank First install a stainless steel well then insert the control aquastat into the well and secure the set screw on the aquastat body or as per the aquastat manufacturer s instructions Thermal paste is recommended but not required The tank water temperature and aquastat setting will be close most of the time but unusual usage patterns may cause the outlet water temperature to rise significantly above the aquastat setting To control fluctuating temperature a thermostatic mixing valve tempering valve must be installed 5 2 AQUASTAT TEMPERATURE Use aquastat to control the maximum water temperature in the tank 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 C higher However in no case should boiler limit control be set above 210 99 18 SERIES INDIRECT WATER HEATERS Installation and Service Manual e Maximum tank temperature is 150 F 5 3 TEM
28. power to the zone valve and the boiler water will be diverted back to the heating zone SERIES INDIRECT WATER HEATERS Installation and Service Manual 2 2 INSTALLATION DIAGRAMS Sample Schematics Boiler Side Piping AR NOTES Il cem UNION ELIMINATOR THIS DRAWING IS MEANT TO SHOW SYSTEM PIPING CONCEPT ONLY INSTALLER IS RESPONSIBLE FOR ALL EQUIPMENT AND DETAILING REQUIRED BY LOCAL CODES SHUT OFF RELIEF gt PUMP pla ae ES VALVE Kj VE uen VALVE BACKFLOW _ _ _ _ _ EXPANSION N PREVENTER TANK Cold Water Fill PIPING SYSTEM FOR EPJ TANKS DEDICATED SINGLE BOILER WITH SINGLE TANK ALLIED ENGINEERING COMPANY 514 01 NOTES fh UNION DRAIN 4 VALVE SHUTOFF _____ NR accu PUMP VALVE ELIMINATOR NI ENSE C o EXPANSION _____ ETE PREVENTER TANK VALVE Cold Water Fill THIS DRAWING IS MEANT TO SHOW SYSTEM PIPING CONCEPT ONLY INSTALLER IS RESPONSIBLE FOR ALL EQUIPMENT AND DETAILING REQUIRED BY LOCA
29. r 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 discharges 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 ELECTRONIC ANODE Most installations do not require the use of an anode however in extremely corrosive water conditions we recommend the use of an Electronic Anode that is non sacrificial e g Corro Protec A sacrificial anode such as magnesium or aluminum is not recommended and may result in accel
30. re when heating Install properly sized potable thermal expansion tank on cold water inlet T amp P Relief valve leaking 22 Replace T amp P relief valve SERIES INDIRECT WATER HEATERS Installation and Service Manual Sf WARRANTY REGISTRATION Section 8 IMPORTANT Registration is required to validate your warranty Option 1 Please visit www alliedboilers com and go to the Warranty Registration section of the website to register your product warranty Option 2 Please fill out the required information on the card below detach insert in an envelope and mail with appropriate postage to Allied Engineering address provided on opposite side of card Note The Serial No and Model can be found on the rating plate The rating plate is located on the jacket of the tank near the sensor well Y CARD MUST BE RETURNED TO VALIDATE WARRANTY Cette forme doit tre compl t e et retourn e pour valider votre garantie Serial No Model No du S rie Modele Date of Purchase Date de l Achat Owner s Name Nom du Propri taire Owner s Address Adresse Installed by Nom de l Installateur Dealer s Name Nom du Distributeur Dealer s Address Adresse du Distributeur NOTE This card must be filled out and mailed within 30 days of purchase to validate your warranty NOTE Cette forme doit tre compl t e et envoy e en dedans 30 trente jours de l achat pour valider votre gar
31. s 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 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 a few 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 Q Dedicated Single Boiler with Single Coil Tank Radiant Floor Baseboard with Port Zone Valve Domestic Priority Radiant Floor Baseboard with 2 Port Zone Valve Domestic Priority Radiant Floor Baseboard Using Circulator and Domestic Hot Waiter Priority Multiple Water Heaters Domestic Priority Q Multiple Wa
32. shut off valve Close hot water faucet after flow is established Resume power 4 T amp P Relief Valve 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 64 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 21 SERIES INDIRECT WATER HEATERS Installation and Service Manual Troubleshooting Guide Section 7 Problem 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 circu
33. ter Heaters Piped in Series Oooo Standard Circulators Zone Run the same as a standard heating zone except one zone is piped to the 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 is connected to the heating zone and the normally closed port is connected to the water heater coil of the tank The boiler water flows through the heating zone until the water heater aquastat demands 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
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