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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. psig by an approved safety or relief valve on your boiler The water heater pressure must be limited to 150 psig maximum by the installation of a temperature and pressure relief valve included The relief tube must be plumbed to a suitable drain per code No reducing coupling or other restriction may be placed in this line

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