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INSTALLATION amp OPERATION INSTRUCTIONS
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SCALDING HAZARD If the water temperature is Electrocution hazard The water heater must be. over 120 F household members can suffer serious electrically grounded in accordance with local codes. or fatal scalding and painful and permanent injury or in the absence of local codes with the National Electrical Code ANSI. The Consumer Products Safety Commission recommends an initial NFPA 70 Electrical supply must come from the boiler side of boiler s. setting of 120 F but advised that a slower response time of infants emergency shut off switch in order to prevent unsafe boiler operation. aged disabled and other persons increases the scalding hazard and If not installed by the boiler manufacturer install a. may require lower settings low water cut off or pressure reducing valve on your. Always check the water temperature before use including washing boiler so that leaking will not result in a dry boiler which if the boiler. bathing or showering continues to fire will cause an explosion hazard. Temperature limiting valves are available from your plumbing supplier This unit must be installed as a separate heating. A check valve must be installed in the boiler return line to prevent zone Do not connect this unit to an existing heating. gravity flow through the heat exchanger This can cause overheating zone or feed boiler water directly through the coil as dangerous. and result in serious or fatal scalding over heating will result. SCALDING HAZARD If the thermostat is not Do not drain this appliance before shutting off the. working properly or if this product is not installed in supply valve and opening the relief valve or. accordance with the manual water temperature can reach excessive another downstream fixture as it will damage this unit A vacuum breaker. levels that may cause serious or fatal scalding After installation and any should be installed to avoid damaging the liner Damage to the unit and. servicing of the unit verify that the thermostat is working and firmly leakage can occur if a vacuum breaker is not installed. inserted in the thermostat well by following the thermostat testing As in all plumbing products and water storage. instructions in the manual vessels bacteria can grow in this Product especially. Failure to use the correct replacement parts may during times of non use Consult your local plumbing professional. make your product unsafe regarding any steps you may wish to take to safely disinfect your home s. plumbing system, In limited circumstances space heating can be lost. in the home with unit utilizing priority mode Any USE GLYCOL ONLY WITH DOUBLE WALLED. demand for space heating is postponed until the water heater has HEAT EXCHANGER MODELS Glycol is a. reached its set temperature This delay in supplying the space heating poisonous substance To avoid seepage or leakage of glycol to. zones is usually not noticed by the inhabitants of the living spaces surfaces where humans or animals can ingest it use glycol only in. However in the event of certain malfunctions such as circulator or double walled units so that any leaks will most likely be released to. thermostat failure space heating could be delayed indefinitely If the atmosphere However a leak to a surface area may still occur. undetected and uncorrected freezing damage to piping could result so any use of glycol must be monitored closely and humans and. animals should be protected from contact with the unit. If a steel hydropneumatic tank is in place replace it. with a properly sized diaphragm expansion tank Do not connect the water heater domestic. Otherwise significant heat transfer problems can occur by causing air to supply with baseboard or other space heating. be trapped in the heat exchanger If the boiler system has a diaphragm units or elements Any contaminants in the baseboard units will. expansion tank and the boiler temperatures are being changed resize the contaminate the potable water in the water heater and also adversely. expansion tank affect its performance, If installing on city water supply a properly sized Do not drill puncture or otherwise penetrate. thermal expansion tank is required with the water the steel outer tank shell Do not screw pipe. heater and should be installed as set fo rth in the product installation hangers or other hardware into the exterior of the tank. manual Contact your water supplier or local plumbing inspector for. additional information, Prevent pressure build up in any existing internal. tankless coil Do not plug incoming or outgoing, tappings in the internal tankless coil plate Leave the coil in the boiler and. leave system connections open to prevent pressure build up. PLEASE READ THE FOLLOWING INSTRUCTIONS CAREFULLY,IMPORTANT GENERAL SAFETY INFORMATION.
ADDITIONAL SPECIFIC SAFETY ALERTS APPEAR IN THE FOLLOWING INSTRUCTIONS. Pre Installation In limited circumstances space heating can. THIS PRODUCT MUST BE INSTALLED AND MAINTAINED BY be lost in the home in this priority mode Any. A LICENSED PROFESSIONAL PLUMBER ELECTRICIAN AS demand for space heating is postponed until the water heater has. APPLICABLE IN ADDITION TO THE INSTRUCTIONS IN THIS reached its set temperature This delay in supplying the space. MANUAL FOLLOW ALL APPLICABLE LOCAL AND STATE heating zones is usually not noticed by the inhabitants of the. CODES INCLUDING MA CMR 248 OR IN THE ABSENCE OF SUCH living spaces However in the event of certain malfunctions such. CODES THE CURRENT EDITIONS OF THE NATIONAL PLUMBING as circulator or thermostat failure space heating could be delayed. CODE AND THE NATIONAL ELECTRIC CODE indefinitely If undetected and uncorrected freezing damage to. piping could result, DRIP PAN AND DRAIN This appliance should not be installed in. an area where leakage of the tank or connections can result in Select Circulator versus Zone Valve. damage to the area adjacent to the appliance or to lower floors of The flow of hot boiler water to the water heater can be controlled with. the structure When such locations cannot be avoided a suitable either a motorized zone valve or a circulator. drain pan adequately drained and kept clear must be installed. under the appliance 1 Separate circulator The recommended way to provide adequate. flow through the water heater heat exchanger is to use a separate. CAUTION Determine whether your water is corrosive or acidic dedicated circulator This option may be used even though the heating. and that there are no suspended solids toxic or other substances system utilizes zone valves. or abnormally high chlorine levels in the water that could damage. or affect the water heater or the rest of your plumbing system 2 Zone valve If a zone valve is to be used a flow rate of 3 to 5 gpm with. all zones in use is required A full port zone valve should be used. Wiring Options Select either a Non Priority or Priority System. Two options are available when wiring the controls of the water heater All installations require a low water cut off or automatic fill valve on your. in the space heating system boiler and distribution elements boiler system to reduce the risk of boiler water loss. 1 Non Priority System The controls of the water heater must be wired Steam boiler installations require a low water cut off which is also. as a separate heating zone with a standard zone valve or a separate required by most codes. circulator dedicated to the water heater zone Installation of a vacuum breaker is required to prevent damage to the. NOTICE In this non priority option the water heater will be supplied water heater when drained There must be no valves installed between. just as another zone This means that if all space heating zones call for the vacuum breaker and water heater. hot boiler water at the same time the water heater may not be supplied. with enough hot boiler water to recover adequately The delivery of. domestic hot water will be diminished In many but not all cases. this is not a problem because the routine oversizing of boiler output is. adequate for both loads, 2 Priority System Under this wiring option the water heater will be. supplied before space heating,Required Components,SHUTOFF VACUUM RELIEF THERMAL EXPANSION. MODEL CIRCULATOR ZONE VALVE DRAIN,VALVE BREAKER VALVE TANK. 4 GPM 3 4 Full Port or, WH SERIES 4 1 Included 41 Gal Models 2 Gal Included.
6 FT 1 STD,4 GPM 3 4 Full Port or 41 Gal Models 2 Gal. CH SERIES 4 1 Included Included,6 FT 1 STD 80 Gal Models 4 4 Gal. IF CIRCULATOR IS NOT USED, ALL INSTALLATIONS REQUIRE AN ADEQUATE AMOUNT OF TEFLON SEALING TAPE OR PIPE DOPE FOR THREADED JOINTS. Heat Exchanger Pressure Drop, Use this chart to select the proper circulator for your BOILERMATE. Pressure Drop Ft,Installation Domestic Water Piping CH Models.
1 Connect the cold water supply to the connection labeled COLD WATER PIPING USING DEDICATED CIRCULATOR PUMP RECOMMENDED. 2 Connect the HOT WATER piping to the domestic hot water system. To Heating Zones, 3 When all domestic water piping is complete open the cold water supply Cold Water Supply. and allow some water to enter the tank Look and listen for signs of Therm X Trol. leaks and repair as necessary before continuing Boiler. 4 Install the temperature pressure relief valve and plumb a blow down Tee. Hot Water Supply, tube to within 6 above a floor drain or as directed by plumbing code EXTROL. Expansion Tank,and Air Purger,Weighted Flow Check,BOILERMATE. Shutoff Valve,Clearance From Combustible Surfaces Zone Returns. Drain or Purge Valve,LEFT SIDE 1 REAR 1 Circulator.
RIGHT SIDE 1 FLOOR 0 Relief Valve,TOP 9 FRONT 1 Blowdown Tube. Clearance for Servicing,LEFT 12 HEAD ROOM 36,RIGHT 12 REAR 1. PIPING USING ZONE VALVE WITH EXISTING HEATING SYSTEM CIRCULATOR. WH Models Heating Zones,Zone Valve Cold Water Supply. Boiler Therm X Trol, PIPING USING SEPARATE CIRCULATOR PUMP RECOMMENDED Supply. System Pump,Hot Water Supply Hot Water Supply,EXTROL Boiler.
Expansion Tank Return,and Air Purger,Hot Water Supply Weighted Flow Check. BOILERMATE,Zone Returns Shutoff Valve,Blowdown Tube Drain or Purge Valve. Expansion Tank,and Air Purger Circulator,Weighted Flow Check. Relief Valve,Shutoff Valve,BOILERMATE,Drain or Purge Valve. Boiler Blowdown Tube,Zone Returns Circulator,Relief Valve.
Boiler Boiler,Cold Water Supply,Therm X Trol,BOILER SUPPLY. PIPING USING ZONE VALVE WITH EXISTING HEATING SYSTEM CIRCULATOR. SUPPLY OUTLET,Hot Water Supply,To Heating Zones BOILER RETURN. BoilerMate,Zone Valve Blowdown Tube,Weighted Flow Check. BOILERMATE,EXTROL Shutoff Valve,Expansion Tank, and Air Purger Drain or Purge Valve Single Wall Models CH 41Z CH 80Z. Circulator,Relief Valve,Zone Returns,HOT OUTLET,Boiler CWS Boiler.
Return Supply,Cold Water Supply,Therm X Trol,BOILER BOILER. SUPPLY RETURN,Double Wall Models CH 41ZDW CH 80ZDW. Installation Boiler Piping, 1 Plumb the circulator or zone valve on the BOILER SUPPLY line. 2 Pipe the BOILER RETURN connection to the boiler return line Zone Valves. Be sure the return line is NOT plumbed to the, suction side of any heating circulators This 3 Wire. may require moving the heating circulator off the boiler tapping on AQUASTAT. packaged boilers Failure to do so will result in overheating and. tank damage when the heating system is in operation. 3 Install a weighted flow check on the boiler return line This is not. necessary on systems utilizing a zone valve to control the water. heater temperature, 4 After completing the boiler piping slowly open the boiler fill valve.
and pressurize the water heater loop Check for leaks and repair as 24VAC. necessary Proceed to the appropriate wiring section in this manual END. EXPLOSION HAZARD Do not install to a high 4 Wire, pressure steam boiler greater than 15 psig AQUASTAT. ZONE VALVE TRANSFORMER,Mechanical Aquastat,Typical Oil Burner Non Priority. HONEYWELL 24VAC,R4222D 1013,OR EQUIVALENT,DPDT RELAY. AQUASTAT 1 3,TRANSFORMER ZONE VALVE,4 6 SWITCH,BOILERMATE. CIRCULATOR,WHEN NO ZR TERMINAL IS AVAILABLE,GO TO THE SUPPLY SIDE OF THE HI LIMIT.
Typical Gas Valves Non Priority,Other Applications. HONEYWELL Multi Zone Control,R4222D 1013,OR EQUIVALENT AQUASTAT. Z DPDT RELAY,AQUASTAT 1 3,BOILERMATE,CIRCULATOR,L2 DHW ZONE Boiler Control Input. 24V Thermostat Input Priority,HONEYWELL BOILERMATE. R4222D 1013 CIRCULATOR,OR EQUIVALENT OR ZONE VALVE.
T DPDT RELAY T,AQUASTAT 1 3,4 6 DHW ZONE,BOILERMATE. CIRCULATOR,L1 BOILERMATE,CIRCULATOR,OR ZONE VALVE,Note if your application is not shown. contact AMTROL Technical Support at 401 535 1216,Installation Digital Control Wiring. 1 Ensure the control installation is within the following application and NOTE Line voltage and safety circuit wiring that is external to the. operating parameters water heater jacket when all panels are in place and which is part of. Ambient temperature from 38 to 125 F the appliance shall be protected by metal conduit metal clad cable or. Relative humidity ranging from 20 to 90 non condensing raceways Thermoelectric wiring shall be exempt from this provision. Boiler load rating up to 15A resistive 1 4hp inductive 120VAC. NOTE Strain relief shall be provided for all conductors leaving an. Circulator load rating up to 15A 1 4hp inductive 120VAC. enclosure For low voltage wiring strain relief at the point of exit from an. Space heating load rating up to 8A 120VAC, enclosure is not necessary if by wire location or support protection is. provided against accidental strain,Oil Burner Controls.
ZR Input Terminal High Limit B Terminal Triple Aquastat. POWER BURNER PUMP PRIORITY POWER BURNER PUMP PRIORITY POWER BURNER PUMP PRIORITY. L2 L1 ZR L2 L1 B L2 L1 R B, BOILERMATE HEATING BOILERMATE HEATING BOILERMATE HEATING. CIRCULATOR CIRCULATOR CIRCULATOR CIRCULATOR CIRCULATOR CIRCULATOR. Gas Valve Controls,24 Volt Millivolt Self Generating. POWER BURNER PUMP PRIORITY POWER BURNER PUMP PRIORITY POWER BURNER PUMP PRIORITY. Z C1 C1 C1,L2 L1 B L2 L1 B2 B L2 L1 B2 B,W C2 C2 C2. BOILERMATE HEATING BOILERMATE HEATING BOILERMATE HEATING. CIRCULATOR CIRCULATOR CIRCULATOR CIRCULATOR CIRCULATOR CIRCULATOR. Other Applications, Multi Zone Control Using Post Purge Multi Zone Control No Post Purge Outdoor Reset Automatic Temperature Control 4 Wire Zone Valve. POWER BURNER PUMP PRIORITY POWER BURNER PUMP PRIORITY. POWER BURNER PUMP PRIORITY POWER BURNER PUMP PRIORITY. BOILERMATE BOILERMATE,CIRCULATOR CIRCULATOR 24VAC,24 OR 120VAC.
L2 L1 L2 L1 ZC ZR,TRANSFORMER ZONE VALVE,DHW ZONE DHW ZONE. ZONE INDRIECT SWITCH,IF EQUIPPED,TO BOILER TO BOILER SELECT INDIRECT. BOILERMATE,CIRCULATOR,OR ZONE VALVE, Note if your application is not shown contact AMTROL Technical Support at 401 535 1216. Installation Digital Control Set Up, Mode After wiring per the appropriate diagram in this manual insert the white. Indicators temperature sensor thermistor plug into the receptacle at the base of. User the digital control Zone valves can be slow actuating Therefore the. Modes zone valve sensor contains a built in temperature offset to account for the. time it takes the zone valve to fully close This results in potable water. temperature that is representative of the digital control temperature set. Installer point This is why it is important to install the correct sensor into the digital. control See Page 3 for information regarding the selection of a circulator. or zone valve,Temperature settings above 120 F can create a.
scald hazard,Front Panel,Wiring Cover,Conduit Holes 3. Ground Screw,Temperature,Sensor Plug, Settings To adjust press and hold the SET button until the Temperature setting appears. Cycle through settings by depressing the SET button and using the and buttons to change the settings. Setting Code Description Range, Temperature Domestic hot water setpoint Default is 120 F 90 150. Differential Domestic hot water temperature drop before call for heat Default is 10 F 5 10. Post Purge Early boiler shutoff prior to hot water setpoint Circulator runs until setpoint Default is 0 F Available only when. Differential setting is 10, Priority Temporarily cancels space heat to maxmize available energy for hot water Default is n y n. Capacity Water heater capacity select appropriate size for proper operation Default is 41 Gallons 26 41 60 80 120. BTU Transfer Real time BTU transfer estimate in 1000 BTU Hr increments Diagnostic readout only 0 199MBH Hr. Diagnostic Error Codes Codes clear automatically when corrected or can be reset by interrupting power to the control for 5 seconds. To silence an alarm depress the on the keypad,Error Code Description Potential Causes.
Sensor unplugged, Temp Sensor Temperature sensor thermistor fault Sensor damaged. Error in boiler plumbing, Overheating Domestic hot water temperature has exceeded maximum setpoint Zone valve stuck open. Leak in sensor well,Faulty equipment, Slow Heating Unit has taken over 60 minutes to reach hot water setpoint or cannot reach setpoint Fouled heat exchanger. Operating Indicators Water sensor temperature may be shown for 30 seconds by pressing. the button,Indicator Code Description, Startup Test Displayed briefly during intial powerup to test LED display segments. Idle Static numeric setpoint readout factory default shown indicates domestic hot water setpoint. Heating Alternating On and Setpoint is displayed during a heating cycle while the circulator pump contacts are closed. Start Up Procedure, 1 Purge Heat Exchanger The heat exchanger should be free of large 2 Fill Tank Open the hot water fixture furthest from the heater Open.
air pockets to allow the circulator to operate properly Using the the cold water supply and allow the water to run until air stops. diagram below as a guide isolate the boiler return line and flush the emerging Air pockets may appear at any hot water fixture This is. loop until large air pockets are purged After this the air elimination considered normal and will clear as hot water is used. equipment will collect smaller air bubbles 3 Start Heater Turn power on to the unit Digital Control models come. pre set to 120 F for safety Mechanical controls should have the knob. rotated to the 120 F mark The circulator or zone valve should operate. Purging Heat Exchanger CH Series Shown and the boiler should start. 4 Check Operation The water heater will begin to heat Depending. upon the size of the water heater output of the boiler and the space. heating load the unit should typically reach set temperature within 15. to 60 minutes If heating does not occur consult the troubleshooting. section in this manual Note Large heaters coupled with small boilers. may exceed this time period upon initial startup, 5 Set Temperature The control should be set to the minimum. temperature consistent with the user s needs This maximizes. efficiency and reduces scald potential,MAINTENANCE. Return 3 Purge The water heater and system should be periodically checked by a. licensed professional at least annually and more often as system ages. 2 Fill CH and WH Models Six 6 year limited warranty on heat exchanger and. tank assembly only Visit www amtrol com for complete warranty details. Troubleshooting,PROBLEM POSSIBLE CAUSES SOLUTION, No hot water 1 No power to unit 1 Check circuit breaker boiler emergency switch and boiler reset switch. 2 Circulator air bound 2 Purge air Ensure circulator is on Boiler Supply Check air vents. 3 Faulty circulator or zone valve 3 Check circulator and zone valve Repair or replace if necessary. 4 Faulty control 4 Check continuity Switching circuits should close If not replace control. 5 Boiler inoperable 5 Check boiler system Boiler must operate to generate hot water. Insufficient hot water 1 Demand exceeds capacity 1 Check sizing based on household size and boiler output. 2 Temperature too low 2 Increase temperature setpoint. 3 Boiler lacks output for simultaneous heat hot water 3 Set up for priority If problem persists add storage or increase tank size. 4 Fouled heat exchanger 4 Check Boiler Supply Boiler Return during cold startup If difference is less. than 20 F clean heat exchanger as outlined below Install water treatment. equipment to prevent recurrence, 5 Insufficient heat exchanger flow 5 Check for undersized or faulty circulator stuck or undersized zone valve. Ensure all shutoff valves are open Check for stuck flow check valve. Purge boiler loop to remove air, Water too hot 1 Improper plumbing 1 If Boiler Return is plumbed to the suction side of a heating circulator.
overheating will occur when the home s heat is on Fix plumbing. 2 Temperature set too high 2 Reduce temperature setting. 3 Temperature sensor not fully inserted 3 Re insert temperature sensor. 4 Stuck zone valve 4 Repair or replace, 5 Flow check valve stuck open 5 Clean repair or replace. Relief valve dripping 1 Thermal expansion tank undersized or missing 1 Install the properly sized thermal expansion tank. or opening 2 Thermal expansion tank set improperly 2 Ensure precharge air pressure matches static water pressure. 3 City pressure too high 3 Install a Pressure Reducing Valve PRV if city pressure is over 80psi. 4 System over temperature 4 Determine cause of over temperature condition and correct problem. 5 Faulty relief valve 5 Replace relief valve, Discolored water 1 Poor water quality 1 Have water tested for contaminants. at faucet 2 Sediment or suspended particles 2 Install sediment filter purge unit more often to avoid future problems. Boiler will not operate 1 Improper or loose wiring 1 Check connections against wiring diagrams in this manual. when calling for 2 Boiler high limit has been reached 2 Boiler will periodically cycle on and off during operation. hot water 3 Post Purge POS set too high 3 Post Purge shuts the boiler off prior to reaching domestic setpoint If set too. 4 Problem with boiler system high the boiler may not have enough energy to raise the water temperature. to setpoint Reduce POS or set to 0 if the problem persists. 4 Have boiler diagnosed for proper operation,Replacement Parts. Description ID WH Series CH Series, Heat Exchanger Replacement WH 41 Single Wall 2700 5000. Heat Exchanger Replacement WH 41 Double Wall 2700 5002. Heat Exchanger Replacement CH 41 Single Wall 2703R003. Heat Exchanger Replacement CH 80 Double Wall 2702R002. Mounting Panel Only Mechanical Control 2 2704R498,Mounting Panel Only Digital Control 3 2704R525.
Mechanical Temperature Control 4 2704 093,Digital Temperature Control w Panel 5 940R101. Temperature Sensor Digital Control 2704 259,Cold Water Inlet Tube CH 41 2703R001. Cold Water Inlet Tube CH 80 2702R001,T P Safety Relief Valve 7 2700R1106 2700R1106. Top Outlet Union Tee 8 2700 635, To obtain replacement parts contact the installer or place of purchase. Technical support is available by calling AMTROL at 401 535 1216. 1400 Division Road West Warwick RI USA 02893,T 800 426 8765 F 800 293 1519.


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