Super Hot EPJ-40-SC Manual

PN11483042
INSTALLATION AND SERVICE MANUAL
EPJ-SERIES INDIRECT WATER HEATERS
FOR MODELS: EPJ-40-SC, EPJ-56-SC, EPJ-79-SC, EPJ-119-SC
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  Telephone [phone]  www.alliedboilers.com
Branches: Calgary  Edmonton  Toronto  Denver
WARNING
Read this manual and all information provided with the appliance before installation,
operation, or service. Failure to follow the instructions may result in severe personal
injury, death or substantial property damage. Installation and service must be
performed by a qualified service technician. Please keep this manual for future
reference.

EPJ SERIES INDIRECT WATER HEATERS – Installation and Service Manual
Table of Contents
Section Page
SECTION 1 - DIMENSIONS AND SPECIFICATIONS ................................................................................. 3
1.1 SPECIFICATIONS .............................................................................................................................. 3
1.2 DIMENSIONS ...................................................................................................................................... 4
1.3 PRESSURE DROP CHART ................................................................................................................ 5
SECTION 2 - PRE-INSTALLATION ............................................................................................................. 6
2.1 RECEIVING ......................................................................................................................................... 6
2.2 INSTALLATION CODES AND REQUIREMENTS ............................................................................... 6
2.3 LOCATION .......................................................................................................................................... 6
2.4 OPERATING RESTRICTIONS............................................................................................................ 7
2.5 WATER QUALITY ............................................................................................................................... 7
SECTION 3 – WATER PIPING ..................................................................................................................... 8
3.1 BOILER WATER PIPING .................................................................................................................... 8
3.2 DOMESTIC WATER PIPING ............................................................................................................. 12
3.3 T&P RELIEF VALVE .......................................................................................................................... 13
3.4 WATER HAMMER ............................................................................................................................. 13
SECTION 4 – WIRING… ............................................................................................................................ 14
SECTION 5 - STARTUP AND ADJUSTMENT .......................................................................................... 19
5.1 PRE-START UP CHECKLIST ........................................................................................................... 19
5.2 STARTUP INSTRUCTIONS .............................................................................................................. 19
SECTION 6 - WATER ADJUSTMENT ....................................................................................................... 20
6.1 CONTROL AQUASTAT ..................................................................................................................... 20
6.2 AQUASTAT TEMPERATURE ........................................................................................................... 20
6.3 TEMPERATURE ADJUSTMENT ...................................................................................................... 21
SECTION 7 - SERVICE AND MAINTENANCE .......................................................................................... 22
7.1 GENERAL OPERATION ................................................................................................................... 22
7.2 ELECTRONIC ANODE ...................................................................................................................... 22
7.3 ANNUAL SERVICE ........................................................................................................................... 23
7.4 MONTHLY SERVICE ........................................................................................................................ 23
SECTION 8 - TROUBLESHOOTING GUIDE ............................................................................................. 24
SECTION 9 - WARRANTY REGISTRATION ............................................................................................. 25
SECTION 10 - NOTES ................................................................................................................................ 27

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Dimensions and Specifications Section 1
1.1 SPECIFICATIONS
Model Storage Capacity (US Gal.) R value (ft
2
h°F/Btu) Shipping Weight (lbs)
EPJ-40-SC 38.9 9.8 66
EPJ-56-SC 55.3 9.8 96
EPJ-79-SC 78.1 9.6 115
EPJ-119-SC 115.0 9.5 189
Note: SC = Single Coil
PERFORMANCE
Model
Boiler
Water Flow
Rate
(US GPM)
Pressure
Drop
Through Coil
(ft. w.c)
1
st
Hour
Delivery
@ 135°F
(US Gal.)
Continuous
Delivery
@ 135°F
(US GPH)
Boiler
Output
Required
(Btu/h)
Standby
Loss
(°F/hr)
EPJ-40-SC
8 2.6 194 160 102,000 0.6
EPJ-56-SC
8 3.2 236 189 119,000 0.5
EPJ-79-SC
13 10.7 348 281 179,000 0.5
EPJ-119-SC
15 7.5 492 391 250,000 0.4
* Note: Ratings are based on 180°F boiler supply and 58°F entering cold water
OPERATING RESTRICTIONS
Maximum Temperature for Tank: 150°F
Maximum Boiler Water Temperature: 210°F
Maximum Working Pressure for Tank: 150 PSIG
MATERIALS OF CONSTRUCTION
Tank: AISI 444 Stainless Steel
Coil: AISI 444 Stainless Steel
Process: Pickled and Passivated for corrosion protection
Insulation: EPS Foam Insulation (2 inch thickness)
Jacket: Polypropylene
Testing: Each tank is Factory Pressure Tested to 300 PSI

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1.2 DIMENSIONS
EPJ DIMENSIONS DIAGRAM
22.5°
45°
F
A
G
COLD WATER
INLET/DRAIN
BOILER WATER
OUTLET
BOILER WATER
INLET
HOT WATER
OUTLET
RELIEF VALVE
SENSOR WELL
E
DC
B
DIMENSIONS (Inches)
Model A B C D E F G
EPJ-40-SC 46 ⅞ 37 25 ¾ 23 ⅝ 10 ¼ 2 21 ⅞
EPJ-56-SC 62 ¾ 52 ¾ 28 ⅞ 26 ¾ 10 ¼ 2 21 ⅞
EPJ-79-SC 69 ¾ 60 ½ 31 28 ⅞ 9 ⅞ 1 ⅞ 23 ¾
EPJ-119-SC 65 ¾ 52 ¾ 39 ⅜ 37 ¼ 11 ½ 2 28 ⅞
CONNECTIONS (NPT)
Model Cold Water
Inlet
Hot Water
Outlet
Boiler Water
Outlet
Boiler Water
Inlet Relief Valve
Sensor Well
EPJ-40-SC ¾" M ¾" M 1" M 1" M ¾" F ½" F
EPJ-56-SC ¾" M ¾" M 1" M 1" M ¾" F ½" F
EPJ-79-SC ¾" M ¾" M 1" M 1" M ¾" F ½" F
EPJ-119-SC 1 ¼" M 1 ¼" M 1 ¼" M 1 ¼" M 1" F ½" F
Notes
1. Aquastat w/ well, T&P Relief Valve, and Combi Tee/Drain Valve supplied as an option.
2. Dimensions and Specifications subject to change without notice.

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1.3 PRESSURE DROP CHART
Boiler Water Pressure Drop through Coil
EPJ-40-SC
EPJ-56-SC
EPJ-79-SC
EPJ-119-SC
0
2
4
6
8
10
12
14
16
0 2 4 6 8 10 12 14 16 18
Pressure Drop (Ft of Head)
Flow Rate (US GPM)

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Pre-Installation Section 2
2.1 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 prevent safe
and proper operation.
2.2 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 indirect water heater must be electrically grounded and
installed 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.
2.3 LOCATION
 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.
 WARNING: The indirect water heater should be located in an area where water leakage of the
tank or its 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, a suitable drain pan must be
installed under the appliance and the drain pan must be connected to a drain of adequate capacity.
Failure to comply with the above could result in severe personal injury, death or substantial property
damage.
 WARNING: Failure to support and stabilize the water heater could result in severe personal injury,
death or substantial property damage. Do not lean items against the water heater. Avoid
unnecessary contact with the water heater.
 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.
 This tank should not be placed where freezing might occur and is not to be installed outdoors.
 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 inches around
the piping connections.
 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.

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2.4 OPERATING RESTRICTIONS
WARNING: The heat transfer medium (including additives, if used) must be water or another non-toxic
fluid 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 limited to 30 PSIG by an approved pressure
relief valve.
The domestic water in the tank must be limited to a maximum temperature of 150°F and maximum pressure
of 150 PSIG by an approved T&P relief valve.
 Maximum Water Temperature for Tank: 150°F
 Maximum Water Temperature for Coil: 210°F
 Maximum Working Pressure for Tank: 150 PSIG
2.5 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.
 PH levels must be between 6.0 and 8.0
 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 indirect water heater.

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Water Piping Section 3
3.1 BOILER WATER PIPING
Connect boiler out (hot) supply piping to the “BOILER WATER IN” fitting on the 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 unions are recommended when
installing your water heater for future service convenience and to prevent galvanic corrosion.
To prevent heat loss due to gravity flow from the coil, a check valve or heat trap with a minimum 12 inch
drop should be installed as close to the “boiler water in” fitting as practical. For systems with two or more
circulators, a check valve may be used to prevent thermal siphoning from circulator draw.
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, the diameter of the pipe between the boiler and tank must be
equivalent to or larger than the diameter of Boiler Water connections on the tank (see section 1.2
Dimensions). There should be no excessive restrictions due to components (e.g. zone valve, check valve,
fittings) or the design of the piping system (e.g. length of run, number of elbows). If a zone valve is used, it
should be a minimum of 1” full port and have a flow coefficient of at least C
V
= 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.
Zone Circulator System
This system is run the same as a standard heating zone except one zone is piped to the water heater and
can be prioritized by using a zone circulator (pump).
Zone Valve System
This system is run the same as a standard heating zone except one zone is piped to the water heater and
can be prioritized by using a zone valve.
3-way Zone Valve System
This system overrides the heat demands of all other zones when there is a heat demand from the water
heater aquastat and diverts all 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
supply side, the normally open port is connected to the heating zones, and the normally closed port is
connected to the “boiler water in” fitting of the water heater. The 3-way valve normally allows boiler water
to flow through the normally open port to the heating zones. When there is a heat demand from the water
heater aquastat, the 3-way valve diverts all boiler water through the normally closed port to the water heater.
Sample Systems
Although there are many possible system designs for your indirect water heater, a few of the most common
are described below. Note that all zones can be controlled by using either circulators or zone valves as long
as the adequate flow is provided. Always ensure that the circulator is correctly sized to provide the required
Boiler Water Flow Rate to the water heater.

Dedicated Single Boiler with Single 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

Multiple Water Heaters – Domestic Priority

Multiple Water Heaters Piped in Series

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3.2 BOILER WATER PIPING DIAGRAMS
BOILER WATER PIPING

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BOILER WATER PIPING

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BOILER WATER PIPING WITH MULTIPLE WATER HEATERS

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3.3 DOMESTIC WATER PIPING
Connect domestic cold water in to the “DRAIN/COLD WATER IN” fitting and the domestic hot water out to
the “HOT WATER OUTLET” fitting. 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 thermowell to the “SENSOR WELL” fitting. The use of shut off valves and brass or dielectric unions are
recommended when installing your water heater for future service convenience and to 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 expansion tank of adequate capacity must be installed in accordance with the
manufacturer’s instructions. Do not install any valve or restrictions between the expansion tank and the hot
water tank. Improper piping of the expansion tank, check valve or backflow preventer could cause excessive
pressure in the tank, tank failure and substantial property damage.
A T&P relief valve must be installed. See section 3.5 T&P Relief Valve for important requirements.
A vacuum breaker can protect the tank from collapse. A vacuum breaker must be installed in the cold water
supply line with or above the highest point in the tank. No valve is to be placed between the vacuum breaker
and the tank. The vacuum breaker manufacturer’s instructions must be followed.
To prevent heat loss due to gravity flow from the tank, a check valve or heat trap with a minimum 12 inch
drop should be installed as close to the “hot water outlet” fitting as practical.
3.4 DOMESTIC WATER PIPING DIAGRAM
Domestic Piping with Optional Recirculation and Thermostatic Mixing Valve

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3.5 T&P RELIEF VALVE
DANGER – Risk of Explosion: A T&P (temperature and pressure) relief valve certified by a nationally
recognized testing laboratory to the requirements of ANSI Z21.22/CSA 4.4 - Relief valves for hot water
supply systems must be installed to protect the tank from excessive temperature and pressure. The T&P
relief valve must have a rating greater than the gross input of the boiler connected to the indirect
water heater. The T&P relief valve must have a maximum temperature setting of 150°F and maximum
pressure setting of 150 PSIG. Do not plug T&P relief valve or discharge piping. Plugging the T&P relief
valve or discharge piping can cause excessive pressure in water heater, resulting in severe personal injury,
death or substantial property damage.
WARNING: The T&P relief valve may discharge pressurized hot water and/or 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.
Temperature and pressure settings of a T&P relief valve are factory set and are not adjustable. The service
pressure should be at least 25 psi less than the setting stamped on the T&P relief valve.
Install the T&P relief valve directly into the T&P relief valve fitting, labeled “RELIEF VALVE”, so that the
temperature sensing element is immersed in water in the top of the tank. No valve, reducing coupling or
other restriction is to be placed between the T&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&P relief valve can cause severe personal injury, death or substantial property damage.
The discharge line must 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. 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, and should terminate freely to atmosphere where any
discharge will be clearly visible and is at no risk of freezing.
3.6 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 do not provide
protection. 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 a maximum water velocity less than
5 ft/s.

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Wiring Section 4
DANGER – RISK OF ELECTROCUTION: Turn off all electric power before attempting any wiring or
service. All electrical supply circuits related to the boiler and tank operation must be switched off.
CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause
improper and dangerous operation.
All wiring must be done in accordance with all applicable local codes or, in the absence of local codes, with
the National Electrical Code ANSI/NFPA 70 (current edition), and/or the Canadian Electric Code CSA C22.1
Part 1 (current edition). They expand on and take precedence over any recommendations in this manual.
If there is any conflict in the above requirements, the more stringent requirement applies.
The indirect water heater must be grounded in accordance with the above requirements.
Wire the aquastat in accordance with the aquastat manufacturer’s instructions. Wiring for the aquastat is
typically connected through the junction box below the aquastat opening. For line voltage connections over
30 volts, wiring must be securely fastened at the junction box opening (field supplied). The aquastat is
typically connected in series with the either a zone valve motor or the coil-side of a relay for switching a
circulator.
Wiring Diagrams
The following wiring diagrams are meant to show concept only. Installer is responsible for all detailing
required by local codes.

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Startup and Adjustment Section 5
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.
5.1 PRE-START UP CHECKLIST

T&P relief valve is properly installed and drain discharge is piped 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.

All wiring is installed correctly, no exposed high voltage wiring is present and the unit is properly
grounded.
5.2 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 purged from both domestic and boiler water systems.
8. Set aquastat on water heater.
9. Power up boiler (following boiler instructions) and water heater.
10. Check boiler is operating normally.
11. Check all zone valves and/or circulators are working properly.
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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Water Adjustment Section 6
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:
Water Temperature Length of Time to Cause Scalding
125ºF (52ºC) 1 1/2 to 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 ½ seconds
Maximum boiler water temperature is 210ºF.
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°C).
Valves for reducing point of use temperature by mixing cold
and hot water are available. Consult a licensed plumber or
local plumbing authority.
WARNING: 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°C) at faucets and a tank temperature not lower than 140°F (60°C) to limit the potential for legionella
pneumophila growth. Contact your local health authority for more information.
6.1 CONTROL AQUASTAT
A control aquastat and thermowell must be installed in order to control the maximum temperature of the
tank. The upper limit of the aquastat’s adjustable range must not exceed 150°F.
First, install the well in the “SENSOR WELL” fitting, then insert the control aquastat into the well and secure
the set screw on the aquastat body or as per the manufacturer’s instructions. Thermal paste is
recommended but not required.
The aquastat will control the tank water temperature within a close tolerance to the aquastat temperature
setting, 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.
6.2 AQUASTAT TEMPERATURE
 Use the aquastat to control the maximum water temperature in the tank.
 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 the aquastat, be sure the boiler operating limit control is
set a minimum of 20°F (11°C) higher than the aquastat setting. However, in no case should the
boiler operating limit control be set above 210°F (99°C).
 Maximum tank temperature is 150°F.