Advance Metalpres J-SERIES User manual

November 2008 price $7.00
J - SERIES
INDIRECT-FIRED WATER HEATERS
INSTALLATION & OPERATIONS
MANUAL
Model…………………………………………………………………………………………..
Serial #...........................................................................................................................
Installed date………………………………………………………………………………….
ADVANCE METALPRES INC
Unit 120-2340 Viscount Way Richmond, BC. CANADA, V6V 1N1
Tel: [phone]. Fax: [phone]
www.metalpres.ca email: [e-mail]
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.

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CONTENTS
Section Page
1 Pre-Installation..........................................................................................................3
1.1 Receiving.................................................................................................................3
1.2 Installation Codes and Requirements......................................................................3
1.3 Location...................................................................................................................3
1.4 Operating Restrictions .............................................................................................4
1.5 Water Quality...........................................................................................................4
1.6 Water Heater Weights and Fitting Sizes..................................................................5
1.7 Dimensions and fitting sizes…………………………………………………………… 6
2. Piping......................................................................................................................7
2.1 Boiler Side Piping ....................................................................................................9
2.2 Installation Diagrams .............................................................................................13
2.3 Domestic Side Piping.............................................................................................12
2.4 Installation Diagrams .............................................................................................13
3. Wiring Diagrams..................................................................................................14
4. Startup Instructions.............................................................................................18
4.1 Pre-startup.............................................................................................................18
4.2 Startup...................................................................................................................18
5. Water Temperature Adjustment..........................................................................19
5.1 Control/Aquastat....................................................................................................20
5.2 Temperature Adjustment .......................................................................................20
6. Maintenance & Service Instructions..................................................................21
6.1 General Operation .................................................................................................21
6.2 Annual Service.......................................................................................................21
6.3 Monthly Service .....................................................................................................22
6.4 Anodes…………………………………………………………………………………….22
7. Specifications......................................................................................................23
8. Troubleshooting Guide .......................................................................................27
9. Notes……………………………………………………………………………………...28

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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. The outer casing has been powder coated
and baked providing the tank with an attractive hardwearing easy clean finish, but it can be
damaged if mishandled. Dropping the tank may dent the casing or prevent proper operation.
It is recommended that a dolly be used to place the tank in its final location.
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
•This tank should not be placed where freezing might occur and is not to be installed
outdoors.
•*Except HR (HORIZONTAL) Series Tanks. 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. See chart in section 1.6 for weight of tank when filled
with water. CAUTION: Failure to support and stabilize the water heater could result in
severe personal injury, death or substantial water damage.
•Although minimal clearance is required for this tank, ensure that there is sufficient room
for the water heater to access all of the fittings easily. We recommend a service
clearance of 24” around plumbing connections.
•CAUTION: 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.

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•This tank must be installed such that any electronic components are protected from
water (dripping, spraying, rain, etc.) during appliance operation and service.
•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.
•For the fastest delivery of hot water, locate the water heater in a position central to the
points of use.
•DANGER - Risk of Explosion: 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.
1.4 OPERATING RESTRICTIONS
CAUTION: 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).This does not apply to the J Series “DW” heat
exchangers which have a double wall with leak detection. The pressure of the heat transfer
medium must be limited to a maximum of 30psi by an approved pressure relief valve.
Maximum working pressure of the tank is 150psi. (Factory test pressure is 300psi.)
1.5 WATER QUALITY
Always use good quality water to prolong the life of the tank. Water which 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.
•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.
Ensure that the softener is regularly maintained.
NOTE: All improper use as detailed above could void the warranty of the tank.

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1.6 WATER HEATER WEIGHTS &DIMENSIONS & FITTING SIZES
* AMI reserves the right to make changes at any time without notice.
WEIGHTS (in
lbs)
Shipped weight
Tank Weight
Domestic Cold Water In
Domestic Hot Water Out
Boiler Water In (supply)
Boiler Water Out (return)
Re
-circulation
Re
-circulation
Aquastat
Pressu
re Relief Valv
Crated Tank Empty Tank Full Water
J40 183 112 446 ¾” ¾” 1” 1” ½” ¾”
J40XL 193 122 456 ¾” ¾” 1 ¼” 1 ¼” ½” ¾”
J40DW 201 132 466 ¾” ¾” 1 ¼” 1 ¼” ½” ¾”
J40DWXL 212 143 478 ¾” ¾” 1 ¼” 1 ¼” ½” ¾”
J40ST/SE
16
5
96
430
¾”
¾”
1 ¼”
1 ¼”
½”
¾”
J60 225 154 654 ¾” ¾” 1” 1” ½” ¾”
J60XL 230 159 659 ¾” ¾” 1 ¼” 1 ¼” ½” ¾”
J60DB 245 165 765 ¾” ¾” 1” 1” ½” ¾”
J60DW 255 176 676 ¾” ¾” 1 ¼” 1 ¼” ½” ¾”
J60DWXL 268 186 686 ¾” ¾” 1 ¼” 1 ¼” ½” ¾”
J60DBXL 265 175 675 ¾” ¾” 1 ¼” 1 ¼” ½” ¾”
J60ST/SE 199 127 627 ¾” ¾” 1 ¼” 1 ¼” ½” ¾”
J60HR 235 166 666 ¾” ¾” 1” 1” ½” ¾”
J60 Kompact 204 145 210 ¾” ¾” 1” 1” ½” ¾”
J80 250 167 834 1” 1” 1 ¼” 1 ¼” ½” ¾”
J80XL 255 174 841 1” 1” 1 ¼” 1 ¼” ½” ¾”
J80DB 270 189 856 1” 1” 1 ¼” 1 ¼” ½” ¾”
J80DW 276 192 859 1” 1” 1 ¼” 1 ¼” ½” ¾”
J80DWXL
285
199
867
1”
1”
1 ¼”
1 ¼”
½”
¾”
J80DBXL 276 197 865 1” 1” 1 ¼” 1 ¼” ½” ¾”
J80ST/SE 240 152 819 1” 1” 2” 2” ½” ¾”
J80HR 292 213 880 1” 1” 1 ¼” 1 ¼” ½” ¾”
J120
310
214
1207
1 ¼”
1 ½
1 ¼”
1 ¼”
½”
¾”
J120XL 320 226 1219 1 ¼” 1 ½ 1 ¼” 1 ¼” ½” ¾”
J120DB 335 240 1229 1 ¼” 1 ½ 1 ¼” 1 ¼” ½” ¾”
J120DW 349 256 1249 1 ¼” 1 ½ 1 ¼” 1 ¼” ½” ¾”
J120DWXL 360 267 1269 1 ¼” 1 ½ 1 ¼” 1 ¼” ½” ¾”
J120DBXL 340 247 1249 1 ¼” 1 ½ 1 ¼” 1 ¼” ½” ¾”
J120ST/SE 300 208 1195 1 ¼” 2” 2” 2” ½” ¾”
J120HR 348 255 1248 1 ¼” 1 ¼” 1 ¼” 1 ¼” ½' ¾”

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1.7
* AMI reserves the right to make changes at any time without notice.
Length
Boiler in
Boiler out
Top Coil Boiler In
Top Coil boiler out
Cold water in / drain
Width
re circ out
re
-circ in
Cw in / Drain
Domestic Hot Water
Out
Domestic Cold
Water In
Boiler Water In
(
supply)
Boiler Water Out
(return)
Re
-circulation
Re
-circulation
Aquastat
Pressure Relief Valv
Z Y X T U V W M N N A B C D C D E H
J40 42½”
24½ “
8” 8¼” 21¼”
¾” ¾” 1” 1” ½” ¾”
J40XL 42½”
22¾ “
8½” 8¼” 21¼”
¾” ¾” 1 ¼”
1 ¼”
½” ¾”
J40DW 42½”
26½ “
8½” 8¼” 21¼”
¾” ¾” 1 ¼”
1 ¼”
½” ¾”
J40DWXL
42½”
26½
“
8½”
8¼”
21¼”
¾”
¾”
1 ¼”
1 ¼”
½”
¾”
J40ST/SE 42½”
8¼” 21¼”
14¼”
8¾”
8 ¼”
¾” ¾” 1¼”
1¼”
½” ¾”
J40HR 42½”
6¾” 6¾” 21¼”
¾” ¾” 1” 1” ½” ¾”
J60 62½”
24½ “
8” 8¼” 21¼”
¾” ¾” 1” 1” ½” ¾”
J60XL 62½”
32” 8¼” 8¼” 21¼”
¾” ¾” 1¼” 1¼” ½” ¾”
J60DB
62½”
24½”
8”
52”
35½”
8¼”
21¼”
¾”
¾”
1”
1”
½”
¾”
J60DW 62½”
32” 9½” 8¼” 21¼”
¾” ¾” 1¼” 1¼” ½” ¾”
J60DWXL 62½”
32” 9½ “ 8¼” 21¼”
¾” ¾” 1¼” 1¼” ½” ¾”
J60DBXL 62½”
27” 8” 51” 32” 8¼” 21¼”
¾” ¾” 1¼” 1¼” ½” ¾”
J60ST/SE
62½”
8¾”
21¼”
14¼”
8¾”
8¾”
¾”
¾”
1¼”
1¼”
½”
¾”
J60HR
62½”
6¾”
6¾”
11¼”
21¼”
¾”
¾”
1”
1”
½”
¾”
J60 Kompact 38” 16 ½”
9½ “ 9½”
27” ¾” ¾”
1” 1” ½” ¾”
J80 66½”
32” 9½” 9½” 23” 1” 1” 1¼” 1¼” ½” ¾”
J80XL 66½”
32” 9½” 9½” 23” 1” 1” 1¼” 1¼” ½” ¾”
J80DB 66½”
29¼”
9¼” 34½”
54½”
9½” 23” 9 ½”
1” 1” 1¼” 1¼” ½” ¾”
J80DW
66½”
33¼”
10¾”
9½”
23”
1”
1”
1¼”
1¼”
½”
¾”
J80DWXL 66½”
33¼”
10¾”
9½” 23” 1” 1” 1¼” 1¼” ½” ¾”
J80DBXL 66½”
29¼”
9¼” 34½”
54½”
9½” 23” 1” 1” 1¼” 1¼” ½” ¾”
J80ST/SE 66½”
9½” 23” 15¾”
9 ½”
9 ½”
1” 1” 2” 2” ½” ¾”
J80HR 66½”
9¾” 9¾” 15¼”
23” 1” 1” 1¼” 1¼” ½” ¾”
J120
70 ½”
32”
9½”
9½”
27”
1½
1¼”
1¼”
1¼”
½”
¾”
J120XL 70 ½”
32” 9½” 9½” 27” 1½ 1¼”
1¼” 1¼” ½” ¾”
J120DB 70 ½”
31 ½”
9½” 36½”
59” 9½” 27” 1½ 1¼”
1¼” 1¼” ½” ¾”
J120DW 70 ½”
32¾”
10¼”
9½” 27” 1½ 1¼”
1¼” 1¼” ½” ¾”
J120DWXL 70 ½”
32¾”
10¼”
9½” 27” 1½ 1¼”
1¼” 1¼” ½’ ¾”
J120DBXL 70½”
29½”
9½” 36½”
59” 9½” 27” 1½ 1¼”
1¼” 1¼” ½” ¾”
J120ST/SE
70½”
15¾”
9½”
27”
15¾”
9 ½”
9 ½”
2”
1¼”
2”
2”
½”
¾”
J120HR 70½”
11” 11” 15¼”
27” 1¼”
1¼”
1¼” 1¼” ½” ¾”

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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 and 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.
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/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.
•Standard Circulator Zone
•Zone Valve System
•3-way Zone Valve System
•Radiant Panel System
•Double Coil
•Multiple Tanks Boiler Piped in Parallel
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.

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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 the water heater aquastat demands, and
diverts all the boiler water 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 divert back to the heating zone.

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Sample Schematics Boiler Side Piping

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Double Coil for larger hot water demand

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Multiple Water Heaters

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2.3 DOMESTIC SIDE PLUMBING
Connect domestic water in and domestic water out to the marked fittings on the water heater.
Use Teflon tape and pipe dope or both on all threaded fittings. Connect drain valve near the
inlet connection so that the tank can be drained. The use of shut off valves and dielectric
unions are recommended when installing your water tank to simplify future service
requirements.
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 & P relief valve
minus 25 P.S.I.
T & P Relief Valve Plumbing
Install the T & P Relief Valve directly into the ¾” tapping located near the top of the tank so
that the temperature sensing element is immersed in the water within the top 6” 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 & 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&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 are factory set and are not adjustable.
DANGER: Do not plug T & P relief valve or discharge piping. Plugging T & P relief valve or
discharge piping can cause excessive pressure in water heater, resulting in severe personal
injury, death or substantial property damage.

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Domestic side piping
Domestic piping with thermostatic mixing valve

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3.0 WIRING DIAGRAMS
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. Turn
off all the power related to the boiler starting and wiring procedures.
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).
CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can
cause improper and dangerous operation.
Wiring diagrams

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4.0 STARTUP AND ADJUSTMENT
DANGER: Before filling the tank make sure that the T & 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.
Pre-startup checklist:
qT&P relief valve is properly installed and drain discharge is directed away to a drain.
qDomestic cold and hot water lines are correctly connected to domestic water system.
qBoiler supply and return piping is correctly connected from boiler to the tank.
qDomestic and boiler water systems are correctly pressurized.
qAll wiring is installed correctly, no exposed high voltage wiring is present and the unit is
properly grounded.
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.

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5.0 WATER TEMPERATURE ADJUSTMENT
DANGER: 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:
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.
Water
Temperature Length of Time to Cause Scalding
125ºF (52ºC) 1
1
/2to 2 minutes
130ºF (54ºC) about 30 seconds
135ºF (57ºC) about 10 seconds
140ºF (60ºC) less than 5 seconds
145ºF (63ºC) less than 3 seconds
150ºF (66ºC) about 1 1/2seconds
Maximum boiler water temperature is 210ºF
WARNING: Studies show that dangerous bacteria, legionella pneumophila, can form in hot
water maintained at 115°F (46°C) or lower. Domestic water temperature lower than 120°F
(49°C) is not recommended to limit the potential for legionella pneumophila growth.

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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.
Aquastat Temperature
•Use the Aquastat to control the maximum water temperature in the tank. Its differential
is fixed at 5ºF (3ºC). Its maximum setting is 160°F (71°C).
•Household water usage patterns will affect water temperature at any faucet or shower.
Always check temperature at every point after adjusting aquastat.
•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 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°F (99°C).
Temperature Adjustment
Allow the water heater to operate several heat-up cycles and check the water temperature at
the faucet to 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 a 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.