TD-41Z | User manual | AMTROL WH Classic Classic Series, Top Down TD Series, RTR models, WHS Premier Series indirect-fired water heater Installation, operation & maintenance instructions

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AMTROL BoilerMate Indirect-fired Water Heater Installation, Operation & Maintenance Instructions | Manualzz

West Warwick, Rhode Island 02893

INSTALLATION, OPERATION

& MAINTENANCE

INSTRUCTIONS

BOILERMATE

®

INDIRECT-FIRED WATER HEATERS

MODELS COVERED:

• WH Classic Series

• Top Down ™ TD Series

• RTR models

• WHS Premier Series

MODELS CODES:

P: Packaged with circulator & Smart Control ™

L: Less Circulator, with Smart Control ™

Z: Dial Aquastat

C: High-output commercial exchanger

DW: Double-wall heat exchanger

RTR: Pre-piped and wired

INSTALLER: LEAVE THIS MANUAL WITH THE OWNER

IMPORTANT GENERAL SAFETY INFORMATION - ADDITIONAL SPECIFIC SAFETY ALERTS APPEAR IN THE FOLLOWING

INSTRUCTIONS.

READ CAREFULLY THE PRODUCT INSTALLATION, OPERATING AND MAINTENANCE MANUAL. FAILURE

TO FOLLOW THE INSTRUCTIONS AND WARNINGS IN THE MANUAL MAY RESULT IN SERIOUS OR

FATAL INJURY AND/OR PROPERTY DAMAGE, AND WILL VOID THE PRODUCT WARRANTY. THIS PRODUCT MUST BE

INSTALLED BY A QUALIFIED PROFESSIONAL. FOLLOW ALL APPLICABLE LOCAL AND STATE CODES AND REGULATIONS,

IN THE ABSENCE OF SUCH CODES, FOLLOW THE CURRENT EDITIONS OF THE NATIONAL PLUMBING CODE AND NATIONAL

ELECTRIC CODE, AS APPLICABLE.

THIS IS THE SAFETY ALERT SYMBOL. IT IS USED TO ALERT YOU TO POTENTIAL PERSONAL INJURY AND OTHER

HAZARDS. OBEY ALL SAFETY MESSAGES THAT FOLLOW THIS SYMBOL TO REDUCE THE RISK OF PERSONAL

INJURY AS WELL AS PROPERTY DAMAGE.

The heat transfer medium must be water or other nontoxic fluid having a toxicity rating or class of 1, as listed in Clinical Toxicology of Commercial Products, 5th edition. The pressure of the heat transfer medium must be limited to 30 PSIG by an approved safety or relief valve.

Part #: 9040-586 (01/09)

1. TABLE OF CONTENTS

2. Pre-Installation Checklist .................................................

2 10. Wiring All Ready-To-Run (RTR) Models .......................

23

3. Required Components and Accessories Checklist .........

3

4. WH-7 & 9 Classic Series Piping Installation ....................

4

5. Top Down™ TD-Series Piping Installation ......................

6

6. Ready-To-Run RTR-Series Piping Installation ................

8

7. WHS Premier Series Piping Installation ........................

10

8. Wiring All Smart Control™ Models ...............................

12

11. Startup Procedure For All Models ................................

25

12. Setting the Smart Control™ ..........................................

26

13. Troubleshooting .............................................................

27

14. Replacement Parts ........................................................

28

15. Cleaning the BoilerMate ® Heat Exchanger ...................

29

16. General Safety Information ...........................................

30

9. Wiring All Dial Control Models (Except RTR Models) .........

20

2. PRE-INSTALLATION CHECKLIST

IMPORTANT STEPS AND DECISIONS REQUIRED BEFORE INSTALLATION

M THIS PRODUCT MUST BE INSTALLED AND

MAINTAINED BY A LICENSED PROFESSIONAL

PLUMBER, ELECTRICIAN, AS APPLICABLE. IN

ADDITION TO THE INSTRUCTIONS IN THIS MANUAL,

FOLLOW ALL APPLICABLE LOCAL AND STATE CODES

INCLUDING MA CMR 248 OR IN THE ABSENCE OF

SUCH CODES, THE CURRENT EDITIONS OF THE

NATIONAL PLUMBING CODE AND THE NATIONAL

ELECTRIC CODE.

space heating zones call for hot boiler water at the same time, the BOILERMATE ® 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

BOILERMATE ® will be supplied before space heating.

M DRIP PAN AND DRAIN: This appliance should not be installed in an area where leakage of the tank or connections can 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, adequately drained and kept clear, must be installed under the appliance.

M CAUTION: Determine whether your water is corrosive or acidic, and that there are no suspended solids, toxic or other substances or abnormally high chlorine levels in the water that could damage or affect the

BOILERMATE ® or the rest of your plumbing system.

In limited circumstances, space heating can be lost in the home in this priority mode. Any demand for space heating is postponed until the BOILERMATE ® has reached its set temperature. This delay in supplying the space heating zones is usually not noticed by the inhabitants of the living spaces. However, in the event of certain malfunctions such as circulator or thermostat failure, space heating could be delayed indefinitely. If undetected and uncorrected, freezing damage to piping could result.

USE GLYCOL ONLY WITH

DOUBLE-WALLED HEAT EXCHANGER

MODELS. Glycol is a hazardous substance. To avoid seepage or leakage of glycol to surfaces where humans or animals can ingest it, use glycol only in double-walled units, so that any leaks will most likely be released to the atmosphere. However, a leak to a surface area may still occur, so any use of glycol must be monitored closely and humans and animals should be protected from contact with the unit.

M Select Circulator versus Zone Valve

The flow of hot boiler water to the BOILERMATE ® can be controlled with either a motorized zone valve or a circulator.

1. Separate circulator. The recommended way to provide adequate flow through the BOILERMATE ® heat exchanger is to use a separate dedicated circulator with a minimum flow rate of 5 gpm. This option may be used even though the heating system utilizes zone valves.

Do not connect the BOILERMATE ® domestic supply with baseboard or other space heating units or elements. Any contaminants in the baseboard units will contaminate the potable water in the BOILERMATE ® and also adversely affect its performance.

2. Zone valve (system flow of 4-8 gpm). If a zone valve is to be used, a minimum flow rate of 5 gpm with all zones in use is required. A full-port zone valve should be used.

M Wiring Options. Select either a Non-Priority or Priority

System:

Two options are available when wiring the controls of the

BOILERMATE ® in the space heating system (boiler and distribution elements).

M All installations require a low-water cut-off or automatic fill valve on your boiler system to reduce the risk of boiler water loss.

M Steam boiler installations require a low-water cut-off which is also required by most codes.

1. Non-Priority System - The controls of the

BOILERMATE ® must be wired as a separate heating zone with a standard zone valve or a separate circulator dedicated to the BOILERMATE ® “zone”.

M Installation of a vacuum breaker is required to prevent damage to the BOILERMATE ® when drained. There must be no valves installed between the vacuum breaker and

BOILERMATE ® .

NOTICE: In this non-priority option, the BOILERMATE ® will be supplied just as another zone. This means that if all

-2-

3. REQUIRED COMPONENTS AND

ACCESSORIES CHECKLIST

MODEL CIRCULATOR ZONE VALVE*

Residential = 5GPM *If Circulator not used

WH SERIES Commercial = 10GPM 3/4” Full Port

Except “P” Models or 1” STD

SHUTOFF VACUUM RELIEF THERMAL EXPANSION

VALVE BREAKER VALVE TANK DRAIN

4 1 Included

Required

(See Therm-X-Trol ®

Sizing Guide)

Included

5GPM

TD SERIES Except “P” Models

*If Circulator not used

3/4” Full Port or 1” STD

RTR SERIES Included N/A

4

4

1

1

Included

Required

(See Therm-X-Trol ®

Sizing Guide)

Included

Included

Required

(See Therm-X-Trol ®

Sizing Guide)

Included

Residential = 5GPM *If Circulator not used

WHS SERIES Commercial = 10GPM 3/4” Full Port

Except “P” Models or 1” STD

4 1 Included

Required

(See Therm-X-Trol ®

Sizing Guide)

ALL INSTALLATIONS REQUIRE TEFLON ® SEALING TAPE OR PIPE DOPE FOR THREADED JOINTS.

SEE HEAT EXCHANGER PRESSURE DROP CHART TO DETERMINE PUMP HEAD REQUIREMENTS.

Use this chart to select the proper circulator for your BOILERMATE

®

.

Included

If a steel hydropneumatic tank is in place, AMTROL ® recommends replacing it with a properly sized EXTROL ® or Radiant EXTROL ® expansion tank. Otherwise, significant heat transfer problems can occur by causing air to be trapped in the heat exchanger. If the boiler system has an EXTROL ® or Radiant EXTROL ® expansion tank and the boiler temperatures are being changed, resize the

EXTROL ® or Radiant EXTROL ® expansion tank.

-3-

4. WH CLASSIC SERIES

PIPING INSTALLATION

DOMESTIC WATER PIPING BOILER PIPING

1. Thread the included

COLD WATER.

2. Screw the tee.

3

4. Temporarily attach the top tee fitting (with o-ring face seal) to the union nut on top of the tank. Test fit the piping near the tee before soldering. Remove the tee before soldering connections to avoid damage to the top o-ring seal or plastic liner.

/

4

3 /

4

” brass tee onto the pipe marked

” drain valve into the opposite end of the brass

3. Connect the cold water supply to the remaining port on the brass tee.

Note: Do not solder piping within 24 inches of the top tee fitting while attached to the tank.

1. Plumb the circulator or zone valve on the BOILER SUPPLY line. If using a separate circulator, the pump flange can be mounted directly to the threaded pipe marked

BOILER SUPPLY. Alternately, the circulator can be placed anywhere on the boiler supply line.

2. Pipe the BOILER RETURN connection to the boiler return line.

Be sure the return line is NOT plumbed to the suction side of any heating circulators. This may require moving the heating circulator off the boiler tapping on 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 BoilerMate ® temperature.

4. After completing the boiler piping, slowly open the boiler fill valve and pressurize the BoilerMate ® loop. Check for leaks and repair as necessary. Proceed to the appropriate wiring section in this manual.

5. Make an 8-inch “heat trap” as shown in the diagram.

This will reduce standby losses from heat migrating up the piping. Continue this line to the domestic hot water system.

6. Install the included T&P relief valve on the top port of the top tee connection. Plumb a blowdown tube to within 6 inches of a floor drain or as directed by plumbing code.

7. When all domestic water piping is complete, open the cold water supply and allow some water to enter the tank. Look and listen for signs of leaks and repair as necessary before continuing.

Note: If installing on a city supply, ensure a dedicated

Thermal Expansion tank (Therm-X-Trol used.

® or equivalent) is

If installing on city water supply a properly sized THERM-X-TROL ® is required with the BoilerMate ® and should be installed as set forth in the THERM-X-TROL ® product installation manual.

Clearance From Combustible Surfaces

LEFT SIDE . . . . . . . . . . . . 1”

RIGHT SIDE . . . . . . . . . . . 1”

TOP . . . . . . . . . . . . . . . . . 9”

REAR . . . . . . . . . . . . . . . . 1”

FLOOR . . . . . . . . . . . . . . . 0”

FRONT . . . . . . . . . . . . . . . 1”

Recommended Clearance For Servicing

LEFT . . . . . . . . . . . . . . . . . 12”

RIGHT. . . . . . . . . . . . . . . . 12”

FRONT . . . . . . . . . . . . . . . 30”

HEAD ROOM . . . . . . . . . . 9”

REAR . . . . . . . . . . . . . . . . 1”

HOT WATER OUTLET

T&P RELIEF VALVE

UNION NUT

BOILER RETURN (Top Left)

BOILER SUPPLY (Top Right)

COLD WATER INLET

(Bottom Center)

-4-

PIPING USING SEPARATE CIRCULATOR PUMP (RECOMMENDED)

PIPING USING ZONE VALVE WITH EXISTING HEATING SYSTEM CIRCULATOR

-5-

5. TOP DOWN

TD-SERIES

PIPING INSTALLATION

DOMESTIC WATER PIPING

1. Connect the cold water supply to the pipe labeled COLD

WATER

2. Connect the HOT WATER piping to the domestic hot water system.

3. Make an 8-inch “heat trap” on the HOT WATER outlet as shown in the diagram. This will reduce standby losses from heat migrating up the piping.

4. When all domestic water piping is complete, open the cold water supply and allow some water to enter the tank. Look and listen for signs of leaks and repair as necessary before continuing.

can be mounted directly to the threaded pipe marked

BOILER SUPPLY. Alternately, the circulator can be placed anywhere on the boiler supply line.

2. Pipe the BOILER RETURN connection to the boiler return line.

Be sure the return line is NOT plumbed to the suction side of any heating circulators. This may require moving the heating circulator off the boiler tapping on 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 BoilerMate ® temperature.

Note: If installing on a city supply, ensure a dedicated

Thermal Expansion tank (Therm-X-Trol ® or equivalent) is used.

5. Install a blowdown tube on the T&P relief valve outlet.

Plumb to within 6 inches above a floor drain or as directed by plumbing code.

BOILER PIPING

4. After completing the boiler piping, slowly open the boiler fill valve and pressurize the BoilerMate ® loop. Check for leaks and repair as necessary. Proceed to the appropriate wiring section in this manual.

If installing on city water supply a properly sized THERM-X-TROL ® is required with the BoilerMate ® and should be installed as set forth in the THERM-X-TROL ® product installation manual.

1. Plumb the circulator or zone valve on the BOILER SUPPLY line. If using a separate circulator, the pump flange

Clearance From Combustible Surfaces

LEFT SIDE . . . . . . . . . . . . 1”

RIGHT SIDE . . . . . . . . . . . 1”

TOP . . . . . . . . . . . . . . . . . 9”

REAR . . . . . . . . . . . . . . . . 1”

FLOOR . . . . . . . . . . . . . . . 0”

FRONT . . . . . . . . . . . . . . . 1”

Recommended Clearance For Servicing

LEFT . . . . . . . . . . . . . . . . . 12”

RIGHT. . . . . . . . . . . . . . . . 12”

FRONT . . . . . . . . . . . . . . . 30”

HEAD ROOM . . . . . . . . . . 9”

REAR . . . . . . . . . . . . . . . . 1”

COLD WATER INLET

(Top Center)

BOILER SUPPLY

(Bottom Right)

BOILER RETURN

(Bottom Left)

T&P RELIEF VALVE OUTLET

HOT WATER OUTLET

-6-

DRAIN VALVE

PIPING USING SEPARATE CIRCULATOR PUMP (RECOMMENDED)

PIPING USING ZONE VALVE WITH EXISTING HEATING SYSTEM CIRCULATOR

-7-

6. READY-TO-RUN RTR-SERIES

PIPING INSTALLATION

DOMESTIC WATER PIPING BOILER PIPING

1. Connect the cold water supply to the pipe labeled COLD

WATER.

1. Plumb the BOILER SUPPLY line. The circulator and flow check are factory installed

2. Connect the HOT WATER piping to the domestic hot water system.

2. Pipe the BOILER RETURN connection to the boiler return line.

3. Make an 8-inch “heat trap” on the HOT WATER outlet as shown in the diagram. This will reduce standby losses from heat migrating up the piping.

4. When all domestic water piping is complete, open the cold water supply and allow some water to enter the tank. Look and listen for signs of leaks and repair as necessary before continuing.

Note: If installing on a city supply, ensure a dedicated

Thermal Expansion tank (Therm-X-Trol used.

® or equivalent) is

Be sure the return line is NOT plumbed to the suction side of any heating circulators. This may require moving the heating circulator off the boiler tapping on packaged boilers. Failure to do so will result in overheating and tank damage when the heating system is in operation.

3. After completing the boiler piping, slowly open the boiler fill valve and pressurize the heat exchanger loop. Check for leaks and repair as necessary. Proceed to the appropriate wiring section in this manual.

5. Install a blowdown tube on the T&P relief valve outlet.

Plumb to within 6 inches above a floor drain or as directed by plumbing code.

COLD WATER INLET

T&P RELIEF VALVE

OUTLET

HOT WATER OUTLET

If installing on city water supply a properly sized THERM-X-TROL ® is required with the BoilerMate ® and should be installed as set forth in the THERM-X-TROL ® product installation manual.

Clearance From Combustible Surfaces

LEFT SIDE . . . . . . . . . . . . 1”

RIGHT SIDE . . . . . . . . . . . 1”

TOP . . . . . . . . . . . . . . . . . 9”

REAR . . . . . . . . . . . . . . . . 1”

FLOOR . . . . . . . . . . . . . . . 0”

FRONT . . . . . . . . . . . . . . . 1”

Recommended Clearance For Servicing

LEFT . . . . . . . . . . . . . . . . . 12”

RIGHT. . . . . . . . . . . . . . . . 12”

FRONT . . . . . . . . . . . . . . . 30”

HEAD ROOM . . . . . . . . . . 36”

REAR . . . . . . . . . . . . . . . . 1”

BOILER SUPPLY

CIRCULATOR

BOILER RETURN

TOP VIEW

DRAIN VALVE

SIDE VIEW

-8-

PIPING MODELS WITH PRE-INSTALLED CIRCULATOR W/INTEGRAL FLOW CHECK

-9-

7. WHS PREMIER SERIES

PIPING INSTALLATION

DOMESTIC WATER PIPING BOILER PIPING

1. Thread one of the included brass tees onto the pipe marked

COLD WATER.

2. Screw the drain valve into the 3/4" outlet of the brass tee.

3. Connect the cold water supply to the remaining port on the brass tee.

4. Thread the other brass tee onto the pipe nipple on top of tank, leaving the 3/4" opening facing up.

5. Thread the included T&P Safety Relief Valve into the top port of the brass tee. Install a blowdown tube to within 6” of the floor drain or as directed by plumbing code.

6. Connect the remaining port on the brass tee to the domestic hot water system.

7. Make an 8-inch “heat trap” as shown in the diagram. This will reduce standby losses from heat migrating up the piping.

8. When all domestic water piping is complete, open the cold water supply and allow some water to enter the tank. Look and listen for signs of leaks and repair as necessary before continuing.

Note: If installing on a city supply, ensure a dedicated

Thermal Expansion tank (Therm-X-Trol ® or equivalent) is used.

Clearance From Combustible Surfaces

LEFT SIDE . . . . . . . . . . . . 1"

RIGHT SIDE . . . . . . . . . . . 1"

TOP . . . . . . . . . . . . . . . . . 9"

REAR . . . . . . . . . . . . . . . . 1"

FLOOR . . . . . . . . . . . . . . . 0"

FRONT . . . . . . . . . . . . . . . 1"

1. Plumb the circulator or zone valve on the BOILER SUPPLY line. If using a separate circulator, the pump flange can be mounted directly to the threaded pipe marked

BOILER SUPPLY. Alternately, the circulator can be placed anywhere on the boiler supply line.

2. Pipe the BOILER RETURN connection to the boiler return line.

Be sure the return line is NOT plumbed to the suction side of any heating circulators. This may require moving the heating circulator off the boiler tapping on 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 BoilerMate ® temperature.

4. After completing the boiler piping, slowly open the boiler fill valve and pressurize the BoilerMate ® loop. Check for leaks and repair as necessary. Proceed to the appropriate wiring section in this manual.

If installing on city water supply a properly sized THERM-X-TROL ® is required with the BoilerMate ® and should be installed as set forth in the THERM-X-TROL ® product installation manual.

Recommended Clearance For Servicing

LEFT . . . . . . . . . . . . . . . . . 12"

RIGHT. . . . . . . . . . . . . . . . 12"

FRONT . . . . . . . . . . . . . . . 30"

HEAD ROOM . . . . . . . . . . 36"

REAR . . . . . . . . . . . . . . . . 1"

HOT WATER OUTLET

BOILER RETURN (Top Left)

BOILER SUPPLY (Top Right)

COLD WATER INLET

(Bottom Center)

-10-

PIPING USING SEPARATE CIRCULATOR PUMP (RECOMMENDED)

PIPING USING ZONE VALVE WITH EXISTING HEATING SYSTEM CIRCULATOR

-11-

8. WIRING ALL SMART CONTROL

MODELS

The Smart Control™ incorporates all the switching and temperature control functions necessary to control the BoilerMate™.

The diagram below shows internal wiring and the associated functions.

After wiring is complete, insert the white thermistor (sensor) plug into the receptacle at the base of the Smart Control™. Select the plug marked CIRCULATOR or ZONE VALVE based on the application. Zone valves can be slow actuating. Therefore, the 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 Smart Control™ temperature set point. This is why it is important to install the correct sensor into the Smart Control™. See Page 2 for information regarding the selection of a circulator or zone valve.

Normally Open

Close on call for hot water

Post-Purge function

Pre-Purge function

{

Normally Open

Close on call for hot water

{

Normally Closed

Open on call for hot water

Priority function

{

Constant 24VAC or 120VAC

{

ORANGE

ORANGE

BLUE

BLUE

VIOLET

VIOLET

WHITE

BLACK

Power In

-12-

1 2

L8124 A & C

T T

L1 L2

BOILERMATE ®

CIRCULATOR

HONEYWELL L8124 A & C

BOILERMATE ®

JUNCTION BOX

ORANGE

ORANGE

BLUE

BLUE

VIOLET

VIOLET

WHITE

BLACK

(PLACE A WIRE NUT OVER

EACH WIRE NOT USED)

ZC

ZR

B2

C2

B1

C1

L8124 B & D

T T

HIGH

LIMIT

B

R

1

LOW LIMIT/

CIRCULATOR

R

W

B

B2

2

B1 C1

C2

L1 L2

L8148A

T T

3

HIGH

LIMIT

B

R

C1 C2

L1 L2

L1 L2

BOILERMATE ®

JUNCTION BOX

ORANGE

ORANGE

BLUE

BLUE

VIOLET

VIOLET

WHITE

BLACK

(PLACE A WIRE NUT OVER

EACH WIRE NOT USED)

BOILERMATE ®

CIRCULATOR

HONEYWELL L8124 B & D

BOILERMATE ®

JUNCTION BOX

ORANGE

ORANGE

BLUE

BLUE

VIOLET

VIOLET

WHITE

BLACK

(PLACE A WIRE NUT OVER

EACH WIRE NOT USED)

B1 B2

HONEYWELL L8148A

BOILERMATE ®

CIRCULATOR

-13-

T W TV

TP Z

L8148J

HI

LIMIT

B

R

B1 B2 B3

C1 C2

L1 L2

T W TV

TP Z

L8148J

HI

LIMIT

B

R

B1 B2 B3

C1 C2

L1 L2

8J48A

TV W T

TP Z B

B1 B2 B3

C1 C2

L1 L2

L1 L2

BOILERMATE ®

CIRCULATOR

HONEYWELL L8148 J

WITH MILLIVOLT GAS VALVE

BOILERMATE ®

JUNCTION BOX

ORANGE

ORANGE

BLUE

BLUE

VIOLET

VIOLET

WHITE

BLACK

(PLACE A WIRE NUT OVER

EACH WIRE NOT USED)

BOILERMATE ®

JUNCTION BOX

ORANGE

ORANGE

BLUE

BLUE

VIOLET

VIOLET

WHITE

BLACK

(PLACE A WIRE NUT OVER

EACH WIRE NOT USED)

L1 L2

BOILERMATE ®

CIRCULATOR

HONEYWELL L8148 J

WITH 24 VOLT GAS VALVE

WHITE - RODGERS 8J48A

WITH 24 VOLT GAS VALVE

BOILERMATE ®

JUNCTION BOX

ORANGE

ORANGE

BLUE

BLUE

VIOLET

VIOLET

WHITE

BLACK

(PLACE A WIRE NUT OVER

EACH WIRE NOT USED)

-14-

8J48A

TV W T

TP Z B

B1 B2 B3

C1 C2

L1 L2

WHITE - RODGERS 8J48 A

WITH 24 VOLT GAS VALVE

BOILERMATE™

JUNCTION BOX

ORANGE

ORANGE

BLUE

BLUE

VIOLET

VIOLET

WHITE

BLACK

(PLACE A WIRE NUT OVER

EACH WIRE NOT USED)

8J48A

TV W T

TP Z B

B1 B2 B3

C1 C2

L1 L2

BOILERMATE ®

JUNCTION BOX

ORANGE

ORANGE

BLUE

BLUE

VIOLET

VIOLET

WHITE

BLACK

(PLACE A WIRE NUT OVER

EACH WIRE NOT USED)

WHITE - RODGERS 8J48A

WITH SELF-GENERATING GAS VALVE

1 2

L8124 A & C

T T

ZC

L1 L2

ZR

B2

C2

B1

C1

HEATING

CIRCULATOR

BOILERMATE ®

CIRCULATOR

PRIORITY WIRING

HONEYWELL L8124 A & C

BOILERMATE ®

JUNCTION BOX

ORANGE

ORANGE

BLUE

BLUE

VIOLET

VIOLET

WHITE

BLACK

L8124 B & D

T

HIGH

LIMIT

T

B

LOW LIMIT/

CIRCULATOR

R

W

R B

1

BOILERMATE ®

JUNCTION BOX

ORANGE

ORANGE

BLUE

BLUE

VIOLET

VIOLET

WHITE

BLACK

B2 B1

2

C1

C2

HEATING CIRCULATOR

L2 L1

-15-

BOILERMATE ®

CIRCULATOR

PRIORITY WIRING

HONEYWELL L8124 B & D

L1

3

L2

L8148A

T

HIGH

LIMIT

B

R

C1 C2

T

B1 B2

L1 L2

L8148B

T T

HIGH

LIMIT

B

R

C1 C2 B1 B2

T W

TP Z

TV

L8148J

HI

LIMIT

B

R

B1 B2 B3

C1 C2

L1 L2

L1 L2

L1 L2

BOILERMATE ®

JUNCTION BOX

ORANGE

ORANGE

BLUE

BLUE

VIOLET

VIOLET

WHITE

BLACK

BOILERMATE ®

CIRCULATOR

PRIORITY WIRING

HONEYWELL L8148A

BOILERMATE ®

JUNCTION BOX

ORANGE

ORANGE

BLUE

BLUE

VIOLET

VIOLET

WHITE

BLACK

BOILERMATE ®

CIRCULATOR

PRIORITY WIRING

HONEYWELL L8148B

BOILERMATE ®

JUNCTION BOX

ORANGE

ORANGE

BLUE

BLUE

VIOLET

VIOLET

WHITE

BLACK

L1 L2

-16-

BOILERMATE ®

CIRCULATOR

PRIORITY WIRING

HONEYWELL L8148 J

WITH 24 VOLT GAS VALVE

T W

TP Z

TV

L8148J

HI

LIMIT

B

R

B1 B2 B3

C1 C2

L1 L2

BOILERMATE ®

JUNCTION BOX

ORANGE

ORANGE

BLUE

BLUE

VIOLET

VIOLET

WHITE

BLACK

8J48A

TV W T

TP Z B

B1 B2 B3

C1 C2

L1 L2

L1 L2

BOILERMATE ®

CIRCULATOR

PRIORITY WIRING

HONEYWELL L8148 J

WITH MILLIVOLT GAS VALVE

HEATING

CIRCULATOR

BOILERMATE ®

JUNCTION BOX

ORANGE

ORANGE

BLUE

BLUE

VIOLET

VIOLET

WHITE

BLACK

(PLACE A WIRE NUT OVER

EACH WIRE NOT USED)

PRIORITY WIRING

WHITE-RODGERS 8J48A

WITH 24VOLT GAS VALVE

BOILERMATE ®

CIRCULATOR

8J48A

TV W T

TP Z B

B1 B2 B3

C1 C2

L1 L2

HEATING

CIRCULATOR

PRIORITY WIRING

WHITE-RODGERS 8J48A

WITH SELF-GENERATING GAS VALVE

-17-

BOILERMATE ®

CIRCULATOR

BOILERMATE ®

JUNCTION BOX

ORANGE

ORANGE

BLUE

BLUE

VIOLET

VIOLET

WHITE

BLACK

(PLACE A WIRE NUT OVER

EACH WIRE NOT USED)

Typical Multi-Zone Relay

Utilizing Post-Purge Feature

X X

Priority or

DHW Zone

Zone Outputs

ORANGE

ORANGE

BLUE

BLUE

VIOLET

VIOLET

BLACK

WHITE

L1 L2

120V

Supply

Smart Control™

(PLACE A WIRE NUT OVER

EACH WIRE NOT USED)

T T

Boiler Aquastat

BoilerMate ®

Circulator

Typical Multi-Zone Relay

24V without Post-Purge Feature

X X

Thermostat

Inputs

Priority or

DHW Zone

24V

Supply

Zone Outputs

ORANGE

ORANGE

BLUE

BLUE

VIOLET

VIOLET

BLACK

WHITE

Smart Control™

(PLACE A WIRE NUT OVER

EACH WIRE NOT USED)

T T

Boiler Aquastat

BoilerMate ®

Circulator

-18-

WATER SENSOR INSTALLATION (IF EQUIPPED)

The Smart Control™ features an error code designed to alert the user to the presence of water on the floor. This is useful to warn of a leaking boiler, water heater, etc., or to alert the owner to a leak in the basement. If equipped with the optional water sensor, follow the installation instructions below:

Water

Sensor

Plug

1. If the sensor will be used to detect a water heater leak, the proper placement is in a drip pan as required in the warning section of this manual. This will both protect the surrounding surfaces from water damage and provide sufficient water depth to activate the alarm. The sensor will function with either side placed toward the floor.

2. If the sensor will be used to detect another potential leak source, such as basement flooding, the sensor must be placed on a flat section of floor in an area where water will first collect. If the level cannot reach 1/32”, the alarm feature may not function. Do not place in a high-traffic area where the sensor could be stepped on or moved. The sensor will function with either side placed toward the floor.

3. After placing the sensor in the appropriate location, plug the water sensor connector into the Smart Control™.

4. Upon wiring the Smart Control™, test the sensor by either immersing it in water or inserting a coin between the two electrodes. The Smart Control should display Er4 and sound an alarm. The error and alarm should disappear when the sensor is dried or the coin is removed. Perform this test during the annual inspection of the BoilerMate ® , or more frequently if installed in an area known to flood.

5. This sensor should not be the primary means of leak detection.

U.S. Patent Pending 11/948,493 and other patents pending.

-19-

9. WIRING ALL DIAL CONTROL MODELS

(EXCEPT RTR MODELS)

Dial Control models utilize a standard dry-contact aquastat with capillary temperature sensor. The dial control contains a make-and-break switch and is suitable for 24V or 120V, 25A Max.

CAPILLARY TUBE

SENSOR BULB

SHAFT

WIRE LEADS

To wire Dial Control models, select the appropriate diagram from the following pages. If a suitable diagram is not available for your application, please contact AMTROL Tech Support at ( 401)535-1216. Always disconnect power before wiring the control.

Ensure that the proper conduit and connectors are used per your local code. In lieu of local code, the National Electric Code should be followed.

SEPARATE CIRCULATOR SEPARATE CIRCULATOR

-20-

ZONE VALVES - SCHEMATIC 3

3-WIRE ZONE VALVES

PRIORITY W/CIRCULATORS - SCHEMATIC 4

Typical Multi-Zone Relay

Priority or

DHW Zone

Zone Outputs

BoilerMate ® Thermostat

X X

T T

Boiler Aquastat

-21-

BoilerMate ®

Circulator

BOILER CONTROL - SCHEMATIC 5

HONEYWELL L8148E

"T"

4 WIRE ZONE VALVE

"T" (ON BOILER CONTROL)

L1 L2

END SWITCH

MOTOR

40VA

TRANSFORMER

24 VOLT

L1

L2

NOTE: TAKE L1 AND L2 OFF THE BOILER CONTROL

ORANGE

ORANGE

BLUE

BLUE

VIOLET

VIOLET

SMART CONTROL™

JUNCTION BOX

BLACK

WHITE

(PLACE A WIRE NUT OVER

EACH WIRE NOT USED IN

THE AMTROL BOILER MATE ®

JUNCTION BOX.)

3 WIRE ZONE VALVE

L1

110v

L2

1

40VA

TRANSFORMER

2

3

24 VOLT

"T"

(ON BOILER

CONTROL)

"T"

L1

L2

NOTE: TAKE L1 AND L2 OFF THE BOILER CONTROL

ORANGE

ORANGE

BLUE

BLUE

VIOLET

VIOLET

BLACK

WHITE

SMART CONTROL™

JUNCTION BOX

(PLACE A WIRE NUT OVER

EACH WIRE NOT USED IN

THE AMTROL BOILER MATE ®

JUNCTION BOX.)

-22-

10. WIRING ALL READY-TO-RUN (RTR) MODELS

Ready-To-Run models include a circulator with built-in priority zoning relay. The aquastat is pre-wired and controls the circulator. Line voltage must be supplied and a signal wire must be run to fire the boiler.

PR

IN

PR

OUT LIVE NEUT

1 2 3 4

DHW AQUASTAT

FACTORY WIRED

LINE IN

LINE OUT

CANCELS ON

CALL FOR DHW

DRY CONTACT

TO BOILER OR

EXTERNAL RELAY

CIRCULATOR RELAY OPERATION

To wire RTR models, select the appropriate diagram from the following pages. If a suitable diagram is not available for your application, please contact AMTROL Tech Support at (401)535-1216. Always disconnect power before wiring the unit. Ensure that the proper conduit and connections are used per your local code. In lieu of local code, the National Electric Code should be followed.

1 2

CIRCULATOR RELAY BOX

PR

IN

PR

OUT LIVE NEUT

3 4

Indirect

Aquastat

L1 L2 T T

HIGH

LIMIT

INPUT

C1 C2

HONEYWELL L8148A OR SIMILAR W/120V HIGH LIMIT

L2

L1

-23-

1 2

CIRCULATOR RELAY BOX

PR

IN

PR

OUT LIVE NEUT

3 4 1 2

CIRCULATOR RELAY BOX

PR

IN

PR

OUT LIVE NEUT

3 4

Indirect

Aquastat

L1 L2 T T

3

REMOVE JUMPER

BETWEEN 1 & 3

C1 C2 HEATING

CIRCULATOR

HONEYWELL L8148A OR SIMILAR W/PRIORITY

L2

L1

Indirect

Aquastat

B

B2 L1 L2

HONEYWELL L8148J W/MILLIVOLT GAS VALVE

L2

L1

1 2

CIRCULATOR RELAY BOX

PR

IN

PR

OUT LIVE NEUT

3 4 1 2

CIRCULATOR RELAY BOX

PR

IN

PR

OUT LIVE NEUT

3 4

Indirect

Aquastat

W

B

L1 L2

WHITE RODGERS 8J48A W/24V GAS VALVE

L2

L1 Indirect

Aquastat

THERMOSTATS T T T T T T

PRIORITY

ZONE MULTI-ZONE

CONTROL

ZONE OUTPUTS

TYPICAL MULTI-ZONE CONTROL

L2

L1

-24-

11. STARTUP PROCEDURE FOR ALL MODELS

1. PURGE HEAT EXCHANGER: The heat exchanger should be free of large air pockets to allow the circulator to operate properly. Using the diagram below as a guide, isolate the boiler return line and flush the loop until large air pockets are purged. After this, the air elimination equipment will collect smaller air bubbles to maximize efficiency.

2. FILL TANK: Open the hot water fixture furthest from the heater. Open the cold water supply and allow the water to run until air stops emerging. Until all air is purged from the hot water system, air pockets may appear at any hot water fixture. This is considered normal and will clear as hot water is used.

If not, check wiring and consult the troubleshooting section in this manual.

4. CHECK OPERATION: The BoilerMate ® will begin to heat. Depending upon the size of the BoilerMate, 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 BoilerMate ® control should be set to the minimum temperature consistent with the user’s needs. This maximizes efficiency and reduces scald potential.

3. START HEATER: Turn power on to the unit. Smart

Control™ models come pre-set at 120°F for safety. Dial units should have the knob rotated to the 120°F mark.

The circulator and boiler should start momentarily.

-25-

12. SETTING THE SMART CONTROL™

The Smart Control™ incorporates multiple features that increase hot water performance and efficiency.

All settings are accessed via the MODE button. To change any setting, simply hold the MODE button then tap to cycle through the settings as outlined below.

GREEN LIGHT - CIRCULATOR INDICATOR

READOUT

DISPLAY

MODE SWITCH

• When power is applied to the unit, the display will show the setpoint temperature (default 120°F).

• Pressing and holding the MODE pushbutton once for 6 seconds will display then 120°F. This is the water temperature setpoint. To raise or lower this temperature setpoint, press the s or t pushbutton. The temperature can be set between 90°F and 150°F. To shut the unit down, scroll below 90°F until 0°F is displayed. Shutting the unit down is beneficial if the water heater will not be used for an extended period of time.

WARNING: Temperature settings above 120°F can create a scald hazard.

• Pressing the MODE pushbutton a second time will cause to be displayed, and releasing the MODE pushbutton will cause 10°F to be displayed. This is the differential setpoint, a setpoint that determines how many degrees the water temperature is allowed to drop before the water heater activates. To change between the available 10°F and 5°F settings, press and release the s or t pushbutton.

• Pressing the MODE pushbutton a third time will cause to be displayed, and releasing the MODE pushbutton will cause 0°F to be displayed. This is the post purge setpoint, a setpoint that allows the boiler to be shut off when the actual water temperature is a certain number of degrees below the setpoint temperature. Since the circulator continues to run, the post purge feature will remove excess heat from the boiler after the boiler shuts off. To change the post purge setpoint, press and release the s or t pushbutton to select 0°F, 4°F, or 8°F below setpoint temperature. NOTE: If the differential is set to 5°F, then the post purge setting will not be available and will automatically be set to 0°F. NOTE: When using the BoilerMate ® on a zone valve application, the post purge feature will not function.

• Pressing the MODE pushbutton a fourth time will cause Pri to be displayed, and releasing the MODE pushbutton will cause ‘y’ to be displayed. This is called the priority setting, a setting that allows the domestic hot water to reach the setpoint temperature before spatial heating is allowed to resume. To disable the ‘priority’ feature, press and release the s or t pushbutton until ‘n’ is displayed.

• Pressing the MODE pushbutton a fifth time will cause to be displayed, and releasing the MODE pushbutton will cause ‘41’ to be displayed. This is the tank volume in gallons. To change this volume, press and release the s or t pushbutton to select the proper tank size (26, 41, 60, 80, or 120 gallons).

• Pressing the MODE pushbutton a sixth time will cause to be displayed, and releasing the MODE pushbutton will cause a number to be displayed. This is a BTU heat transfer rate estimate in MBH. This is a diagnostic readout and cannot be changed.

NOTE: Any changes made to the above settings will take effect after 10 seconds. This will be acknowledged by a display of

. Thereafter, these changes will be the new control settings even in the event of a power outage.

• An approximation of the actual domestic water temperature in the tank can be displayed in °F by pressing the s pushbutton.

• One or more error messages will be displayed if abnormal operation occurs, and an audible alarm will sound for most error messages. The audible alarm can be silenced by pressing the t pushbutton. An damaged thermistor (temperature sensor). Check and replace as necessary. An

message indicates an unplugged or

message appears when the stored water temperature exceeds 155°F. Contact your service person to correct the problem. An Er3 message indicates that the actual domestic water temperature did not reach the setpoint temperature after one hour of attempted heating. Contact your service person to correct the problem. For models equipped with a water sensor, an Er4 message indicates that a water puddle has been detected. Contact your service person to correct the problem.

Note: Smart Control ™ is to be used for indoor applications only. Do not operate the Smart Control ™ unit outside of the following ranges:

• Ambient temperature from 38°F to 125°F.

• Relative humidity ranging from 20% to 90% (non-condensing).

• Boiler load rating up to 15A resistive, 1/4hp inductive @120VAC.

• Circulator load rating up to 15A resistive, 1/4hp inductive @120VAC.

• Space heating load rating up to 8A @ 120VAC.

Note: For models equipped with a water sensor, the water sensor should be placed flat on the floor in a low-traffic area. On a regular basis, verify that the water sensor is functioning properly by placing the orange puck in a water puddle or inserting a coin between the two electrodes and listening for an audible alarm. This water sensor should not be the primary means of leak detection. See water sensor installation page for more details.

Note: If setpoints were being adjusted when a power outage occurred, then recheck all set points after power has been restored.

-26-

PROBLEM

No hot water

Insufficient hot water

13. TROUBLESHOOTING

1. No power to unit

2. Air in heat exchanger loop

3. Faulty circulator or zone valve

4. Faulty BoilerMate™ thermostat

5. Faulty Smart Control™

6. Boiler inoperable

1. Demand exceeds capacity

2. Temperature too low

3. Boiler lacks sufficient output

4. Fouled heat exchanger

5. Insufficient heat exchanger flow

SOLUTION

1. Check circuit breaker, boiler emergency switch and boiler reset switch

2. Purge air. Ensure circulator is on Boiler Supply. Check air vents

3. Check circulator and zone valve. Repair or replace if necessary

4. Check continuity while rotating knob. Circuit should open and close.

5. If blank, check power. Check continuity across two orange and two blue leads while green light is on. If none, open control and replace fuses or replace control.

6. Check boiler system. Boiler must operate to generate hot water

1. Check sizing based on household size and boiler output

2. Increase temperature setpoint

3. Wire for priority. If problem persists add storage or increase tank size.

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. 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.

1. Improper plumbing

Water too hot and/ or ER2 message on

Smart Control™

2. Temperature set too high

3. Temperature sensor not fully inserted

4. Stuck zone valve

5. Flow check valve stuck open

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. Reduce temperature setpoint

3. Re-insert thermistor wire or temperature sensor.

4. Repair or replace

5. Clean, repair or replace

Noise from

BoilerMate ®

1. Air in boiler loop

2. Faulty circulator pump

3. Thermal expansion

4. Normal noise during initial fill

1. Purge boiler loop. Check air elimination equipment.

2. Repair or replace pump

3. Ensure the proper Therm-X-Trol ® or equivalent thermal expansion tank is installed and adjusted properly

4. When first pressurized, a creaking or hissing sound is normal. After pressurizing, the noise should stop. Always check for leaks.

Relief valve dripping or opening

1. No thermal expansion tank

2. Thermal expansion tank set improperly

3. City pressure too high

4. System over temperature

5. Faulty relief valve

1. Install the proper Therm-X-Trol ® or equivalent thermal expansion tank

2. Ensure precharge air pressure matches static water pressure

3. Install a Pressure Reducing Valve (PRV) if city pressure is over 80psi

4. Determine cause of over temperature condition and correct problem

5. Replace relief valve

ER1 message on

Smart Control™

1. Temperature sensor unplugged

2. Temperature sensor cut or faulty

3. Water in therm-well

1. Sensor is unplugged from factory. Plug into Smart Control™ receptacle

2. Replace sensor wire (thermistor)

3. Replace therm-well

1. Poor water quality

Discolored water at faucet

2. Sediment or suspended particles

1. Have water tested for contaminants. Typical problems are:

Blue/green color = copper discoloration due to low pH

Black staining/sulfur odor = hydrogen sulfide

White deposits = hard water

Red staining = high iron levels

2. Install sediment filter, purge unit more often to avoid future problems

Boiler will not operate when calling for hot water

1. Improper or loose wiring

2. Boiler high limit has been reached

3. Fuse blown in Smart Control™

4. Post Purge (POS) set too high

5. Problem with boiler system

1. Check connections against wiring diagrams in this manual

2. Boiler will periodically cycle on and off during operation

3. Remove 4 screws inside the Smart Control™ wiring box. Replace glass fuse(s) with those of the same rating

4. Post Purge shuts the boiler off prior to reaching domestic setpoint. If set too 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

5. Have boiler diagnosed for proper operation

Circulator or zone valve will not operate when calling for hot water

1. Improper or loose wiring

2. Pre Purge (PRE) set too high

3. Fuse blown in Smart Control™

4. Faulty circulator pump

1. Check connections against wiring diagrams in this manual

2. PRE setting delays circulator startup. This is not normally needed in residential applications. Reduce PRE or set to 0 if problem persists

3. Remove 4 screws inside the Smart Control™ wiring box. Replace glass fuse(s) with those of the amp same rating

4. Repair or replace pump

-27-

14. REPLACEMENT PARTS

Single Wall Heat Exchanger

w/Gasket and Nuts

Double Wall Heat Exchanger

w/Gasket & Nuts

Commercial Heat Exchanger

w/Gasket & Nuts

Top Outlet Tee

w/O-Ring

Flange Gasket:

Bottom & Top

Thermo-Well

Assembly

Top Outlet O-Ring or

Bottom Drain O-Ring

Smart Control™

Sensor (thermistor)

wire

Dial Aquastat

(residential)

Dial Aquastat

(commercial)

Conversion Kit:

Dial Aquastat

to Smart Control™

Conversion Kit:

Smart Control™ to

Dial Aquastat

Circulator Pump

Water Sensor

WH-7, 41 WHS 60 & 80 WHS 120 WHS 60 & 80 WHS 120 and 9 Series TD-7 Series TD-7 RTR TD-80 Series Residential Residential Commercial Commercial

2700-5000

2700-5002

2700-5001

2700-635

2704-403

2700-5005

2700-5006

N/A

N/A

2704-403

2700-5007

N/A

N/A

N/A

2704-403

2700-924 2700-924(exc DW) 2700-924

2500-178

2704A233

2704-259

2704-093

N/A

2704-227

2704-392

245-58

2704-495

2500-178

2704A233

2704-259

2704-093

N/A

2704-227

2704-392

245-58

245-58

2500-178

2704A233

2704-259

2704-093

N/A

N/A

N/A

245-62

245-62

2700-5008

N/A

N/A

N/A

2704-403

2700-1167

2500-178

2704A233

2704-259

2704-093

N/A

2704-227

2704-392

245-58

245-58

2775-82

2775-83

N/A

N/A

2704-403

2700-924

N/A

2704A233

2704-259

2704-093

2775-454

2775-389

2775-455

245-58

245-58

2775-81

2775-83

N/A

N/A

2704-403

2700-924

N/A

2704A233

2704-259

2704-093

2775-454

2775-389

2775-455

245-58

245-58

2700-5001

2775-84

See Above

N/A

2704-403

2700-924

N/A

N/A

N/A

N/A

2775-454

2775-389

2775-455

N/A

N/A

2700-5001

2775-84

See Above

N/A

2704-403

2700-924

N/A

N/A

N/A

N/A

2775-454

2775-389

2775-455 plus 2775-454 plus 2775-454

N/A

N/A

To obtain replacement parts, contact the installer or place of purchase. Technical support is available by calling

AMTROL at (401) 535-1216.

-28-

15. CLEANING THE BOILERMATE

®

HEAT EXCHANGER COIL

A diminished temperature difference between the boiler water entering and leaving the heat exchanger coil may indicate heat exchanger scale buildup. Water treatment equipment and proper maintenance will help to avoid this problem. To clean a scaled heat exchanger coil proceed as follows:

7. Set the temperature control to its highest setting and operate the unit until the control is satisfied. Note:

Boiler may cycle on its high limit several times during this period. If the tank temperature setting has not been satisfied after 45 minutes of boiler operation, turn the

BoilerMate ® control off to stop boiler operation.

1. Shut off the cold water supply to the

BoilerMate ® .

8. Allow heated solution to set in tank for 30 minutes, then drain tank completely using fitting and hose, as required.

2. Make a note of the temperature control setting on the BoilerMate

3. Relieve the water pressure in the tank by opening a hot water faucet. This will reduce the risk of scalding injury.

10. Reinstall the safety relief valve.

BoilerMate ®

® , then turn the unit off.

4. Remove the relief valve from the top of the

, taking care to avoid contact with the hot water, which may drain out of the plumbing.

9. Fill water tank with fresh, cold, conditioned water and drained completely at least two times or until drained water runs clear.

11. Open the cold water supply and fill the tank with water.

Purge plumbing by operating all hot and cold water fixtures in the building.

12. Return the control to the setting noted in Step 2 and verify that the unit is functioning properly.

5. Drain the BoilerMate ® until the water within the tank is even with the top of the heat exchanger

- approximately 15 gallons for 41-gallons units and 5 gallons for 26-gallon units.

As an alternative to the above, the heat exchanger may be removed from the BoilerMate is removed.

® and cleaned. A new gasket must be installed whenever the heat exchanger

Do not over-drain the tank.

Improper thermostatic control could result during Step 6 and lead to damage to the BoilerMate ® .

6. Using a funnel, pour one gallon of nontoxic commercial phosphoric acid solution

(commercial icemaking cleaning solution) into the water tank through the top opening. Be sure that the manufacturer’s directions and warnings are followed.

-29-

15. GENERAL SAFETY INFORMATION

SCALDING HAZARD. If the water temperature is over 120°F, household members can suffer serious or fatal scalding and painful and permanent injury. • The Consumer Products Safety

Commission recommends an initial setting of 120°F, but notes a slower response time of infants, aged, disabled and other persons increases the scalding hazard and may require lower settings. • Always check the water temperature before use, including washing, bathing or showering. • Temperature limiting valves are available from your plumbing supplier. A check valve must be installed in the boiler return line to prevent gravity flow through the heat exchanger. This can cause overheating and result in serious or fatal scalding.

SCALDING HAZARD. If the thermostat is not working properly or if this product is not installed in accordance with the manual, water temperature can reach excessive levels that may cause serious or fatal scalding. After installation and any servicing of the unit, verify that the thermostat is working and firmly inserted in the thermostat well by following the thermostat testing instructions in the manual.

Note: Inspect for shipping damage and notify freight carrier or store where purchased immediately if damage present.

To avoid risk of personal injury and property damage, if the product appears to be malfunctioning or shows signs of corrosion, call a qualified professional immediately. Current copies of the Product manual can be viewed at www.amtrol.

com. Use proper safety equipment when installing.

EXPLOSION HAZARD. The pressure of the heat transfer medium must be limited to a maximum of 30 psig by an approved safety or relief valve on your boiler. The BoilerMate ® 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.

Failure to use the correct replacement parts may make your product unsafe.

CALIFORNIA PROPOSITION 65

WARNING! WARNING: This product contains a chemical known by the State of California to cause cancer and birth defects or other reproductive harm. (California Installer/Contractor - California law requires that this notice be given to consumer/end user of this product.) For more information: www.amtrol.com/ prop65

In limited circumstances, space heating can be lost in the home with unit utilizing priority mode. Any demand for space heating is postponed until the Boiler Mate ® has reached its set temperature. This delay in supplying the space heating zones is usually not noticed by the inhabitants of the living spaces.

However, in the event of certain malfunctions such as circulator or thermostat failure, space heating could be delayed indefinitely. If undetected and uncorrected, freezing damage to piping could result.

This Product, like most Products under pressure, may over time corrode, weaken and burst or explode, causing serious or fatal injury, leaking or flooding and/or property damage. To minimize risk, a licensed professional must install and periodically inspect and service the Product. A drip pan connected to an adequate drain must be installed if leaking or flooding could cause property damage. Do not locate in an area where leaking could cause property damage.

EXPLOSION OR RUPTURE HAZARD.

A relief valve must be installed to prevent pressure in excess of local code requirement or maximum working pressure designated in the Product Manual, whichever is less. Do not expose Product to freezing temperatures or temperatures in excess of the maximum rated operating temperature.

reducing valve on your boiler so that leaking will not result in a dry boiler which if the boiler continues to fire, will cause an explosion hazard.

If not installed by the boiler manufacturer, install a low water cut-off or pressure

If a steel hydropneumatic tank is in place, AMTROL ® recommends replacing it with a properly sized EXTROL ® expansion tank.

Otherwise, significant heat transfer problems can occur by causing air to be trapped in the heat exchanger. If the boiler system has an EXTROL ® or Radiant EXTROL ® expansion tank and the boiler temperatures are being changed, resize the

EXTROL ® or Radiant EXTROL ® expansion tank.

This unit must be installed as a separate heating zone. Do not connect this unit to an existing heating zone or feed boiler water directly through the coil as dangerous over-heating will result.

If installing on city water supply a properly sized THERM-X-TROL ® is required with the BoilerMate ® and should be installed as set fo rth in the THERM-X-TROL ® product installation 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.

Electrocution hazard. The BoilerMate ® must be electrically grounded. Electrical supply must come from the boiler side of boiler’s emergency shut-off switch in order to prevent unsafe boiler operation.

Do not drain this appliance before shutting off the supply valve and opening the relief valve or another downstream fixture, as it will damage this unit. A vacuum breaker should be installed to avoid damaging the liner. Damage to the unit and leakage can occur if a vacuum breaker is not installed.

USE GLYCOL ONLY WITH

DOUBLE-WALLED HEAT

EXCHANGER MODELS. Avoid risk of ingesting a toxic glycol fluid. The heat transfer medium should be water. If glycol must be used, it should only be used with double-walled heat exchangers and closely monitored for leakage.

Chlorine Aggressive Water: The water quality can significantly influence the life of this Product. You should test for corrosive elements, acidity, total solids and other relevant contaminants, including chlorine and treat your water appropriately to insure satisfactory performance and prevent premature failure.

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-31-

West Warwick, Rhode Island 02893

BoilerMate, AMTROL, AMTROL logo, Therm-X-Trol, Radiant EXTROL and EXTROL are registered trademarks of AMTROL Inc. and affiliates. All rights reserved.

Part #: 9040-586 (01/09)

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Key Features

  • Indirect-fired water heating
  • Tank-style design
  • Boiler system compatibility
  • Energy efficiency
  • Smart Controlâ„¢ option (some models)
  • Priority zoning (some models)
  • Safety features (T&P relief valve, low-water cutoff)
  • Easy installation and maintenance

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Frequently Answers and Questions

What is an indirect-fired water heater?
An indirect-fired water heater uses a boiler to heat water for domestic use. This is in contrast to a direct-fired water heater that uses a gas or electric burner to directly heat water.
What are the benefits of using an indirect-fired water heater?
Indirect-fired water heaters offer several benefits including energy efficiency, quieter operation, and longer lifespan compared to direct-fired water heaters.
What is the Smart Controlâ„¢?
The Smart Controlâ„¢ is an optional control system available on some AMTROL BoilerMate models. It provides features like temperature setpoint adjustment, post-purge function to remove excess heat from the boiler, and priority zoning to ensure hot water is available even when the heating system is running.
What is priority zoning?
Priority zoning is a feature that ensures hot water is available even when the heating system is running. The BoilerMate will prioritize hot water production over space heating when hot water is needed.
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