Amtrol | TD-41Z | Installation guide | Amtrol TD-41Z Installation guide

West Warwick, Rhode Island 02893
INSTALLATION, OPERATION
& MAINTENANCE
INSTRUCTIONS
TM
BOILER MATE TOP-DOWN
INDIRECT-FIRED WATER HEATERS WITH
TOP-MOUNTED COIL
MODELS: TD-7Z
TD-41Z
TD-7ZDW
TD-41ZDW
The heat transfer medium should be water. If any product other than water is used, it must be a
non-toxic fluid suitable for human ingestion as determined by the FDA
WARNING: REVIEW ALL GENERAL SAFETY INFORMATION ON PAGE 3 PRIOR TO INSTALLATION.
Your AMTROL BOILER MATE™ has been carefully assembled and factory tested. To enjoy the full service your BOILER
MATE™ can provide, you should read and follow all of the instructions in this manual. When all installation steps have
been completed, make sure you also follow the enclosed post-installation and start-up checklists before using your
AMTROL product. You should also read carefully the sections describing proper product maintenance, and follow the
required procedures as you use your BOILER MATE™. Return this booklet to its original envelope, and keep it with the
BOILER MATE™. This manual may become out-of-date by later amendments. Check our web site,
www.amtrol.com or ask your AMTROL supplier for any updates relating to your product.
Our goal is to ensure you are fully satisfied with your new BOILER MATE™. If any questions or concerns arise, call
Technical Service at 401-535-1216.
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 POSSIBLE INJURY AS WELL AS PROPERTY DAMAGE.
Part #: 9040-628 REV B (7/04)
-1-
TABLE OF CONTENTS
1. GENERAL SAFETY INFORMATION......................................................................................3
2. PRE-INSTALLATION CHECKLIST ........................................................................................4
Important Steps and Decisions Required Before Installation
3. REQUIRED COMPONENTS AND ACCESSORIES CHECKLIST .......................................5
FORCED HOT WATER, CLOSED HYDRONIC HEATING SYSTEMS
4. INSTALLATION - Forced Hot Water, Closed Hydronic Heating System .........................6
A. General Installation Requirements ..................................................................................6
B. Piping .................................................................................................................................7
C. Electrical Wiring ................................................................................................................8
D. Post-Installation and Start-up Check List.......................................................................9
ALL SYSTEMS
6. OPERATION AND MAINTENANCE.....................................................................................11
7. REPLACEMENT PARTS.......................................................................................................12
8. TROUBLESHOOTING CHECKLIST ....................................................................................13
9. SERVICE RECORD...............................................................................................................14
10. AMTROL LIMITED PRODUCT WARRANTY......................................................................15
-2-
1. GENERAL SAFETY INFORMATION
IMPORTANT GENERAL SAFETY INFORMATION - ADDITIONAL SPECIFIC SAFETY ALERTS
APPEAR IN THE FOLLOWING INSTRUCTIONS
EXPLOSION HAZARD: DO NOT INSTALL TO A HIGH PRESSURE STEAM BOILER (greater than 15
psig). AN EXPLOSION COULD OCCUR.
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
TANK PRESSURE MUST BE LIMITED TO 150 PSIG MAXIMUM BY THE INSTALLATION OF A
TEMPERATURE AND PRESSURE RELIEF VALVE (INCLUDED).
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 HAZARD TO THEM 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.
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 SCALDING, EVEN IF THE TEMPERATURE SETTING IS CORRECT.
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
AFTER INSTALLATION AND ANY SERVICING OF THE UNIT.
SCALDING HAZARD: A CHECK VALVE MUST BE INSTALLED IN THE BOILER RETURN LINE TO
PREVENT GRAVITY FLOW THROUGH THE HEAT EXCHANGER. THIS CAN CAUSE OVER HEATING
AND RESULT IN SERIOUS SCALDING.
IF NOT INSTALLED BY THE BOILER MANUFACTURER, INSTALL A LOW WATER CUT-OFF OR
PRESSURE REDUCING VALVES MUST BE INSTALLED ON YOUR BOILER SO THAT LEAKING FROM
ANY PLUMBING FIXTURE WILL NOT RESULT IN A DRY BOILER; IF THE BOILER CONTINUES TO
FIRE, AN EXPLOSION HAZARD EXISTS.
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.
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.
ALSO, MAKE SURE A VACUUM BREAKER IS IN PLACE TO AVOID DAMAGING THE LINER.
AVOID RISK OF INGESTING A TOXIC FLUID. THE HEAT TRANSFER MEDIUM SHOULD BE WATER.
IF GLYCOL MUST BE USED, IT SHOULD ONLY BE USED WITH DOUBLE-WALLED HEAT
EXCHANGERS.
THIS TANK, LIKE MOST TANKS UNDER PRESSURE, WILL OVER TIME CORRODE OR FAIL AND/OR
MAY BURST AND/OR LEAK OR FLOOD (AND IN RARE CASES EXPLODE) WHICH CAN CAUSE
SERIOUS OR FATAL PERSONAL INJURY AND PROPERTY DAMAGE. TO MINIMIZE RISK, A
LICENSED PROFESSIONAL MUST INSTALL AND PERIODICALLY INSPECT AND SERVICE THE UNIT. A DRIP PAN,
CONNECTED TO AN ADEQUATE DRAIN MUST BE INSTALLED IF LEAKING OR FLOODING CAN CAUSE PROPERTY
DAMAGE.
AS IN ALL PLUMBING PRODUCTS AND WATER STORAGE VESSELS, BACTERIA CAN GROW IN
YOUR BOILER MATE TM, ESPECIALLY DURING TIMES OF NON-USE. CONSULT YOUR LOCAL
PLUMBING OFFICIAL REGARDING ANY STEPS YOU MAY WISH TO TAKE TO SAFELY DISINFECT
YOUR HOME’S PLUMBING SYSTEM.
WATER QUALITY CAN SIGNIFICANTLY INFLUENCE THE LIFE OF YOUR 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.
FOLLOW ALL OF THE INSTRUCTIONS AND RECOMMENDATIONS CONTAINED IN THIS MANUAL,
AND THE FOLLOWING ADDITIONAL SPECIFIC WARNINGS. FAILURE TO DO SO IS UNSAFE AND
CAN CAUSE SERIOUS SCALDING, EXPLOSION, SERIOUS OR FATAL PERSONAL INJURY AND
PROPERTY DAMAGE.
FAILURE TO FOLLOW THE ABOVE WARNINGS MAY RESULT IN SERIOUS OR FATAL PERSONAL INJURY
AND/OR PROPERTY DAMAGE, AND WILL VOID THE WARRANTY.
-3-
2. PRE-INSTALLATION CHECKLIST
IMPORTANT STEPS AND DECISIONS REQUIRED BEFORE INSTALLATION
2. Priority System - Under this wiring option the
BOILER MATE™ will be supplied before space
heating.
THIS PRODUCT MUST BE INSTALLED AND
j
MAINTAINED BY A LICENSED PROFESSIONAL. IN ADDITION
TO THE INSTRUCTIONS IN THIS MANUAL, FOLLOW ALL
APPLICABLE LOCAL AND STATE CODES OR IN THE
ABSENCE OF SUCH CODES, THE CURRENT EDITIONS OF
THE NATIONAL PLUMBING CODE AND THE NATIONAL
ELECTRIC CODE.
In limited circumstances, space
heating can be lost in the home in
this 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.
j DRIP
PAN AND DRAIN: To avoid leaking and/or
property damage, install with a drip pan connected to
an adequate working drain kept clear at all times.
j 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 BOILER
MATE™ or the rest of your plumbing system.
j Select Circulator versus Zone Valve
The flow of hot boiler water to the BOILER MATE™ can be
controlled with either a motorized zone valve or a
circulator.
Do not locate this product where
leaking and flooding could cause
damage to surrounding property.
1. Zone valve (system flow of 4-8 gpm). If a zone valve is to
be used, a minimum flow rate of 4 gpm with all zones in
use is required with a maximum of 8 gpm with only the
BOILER MATE™ in use. Be sure the zone valve chosen has
a maximum pressure drop (Cv = 4) when fully opened.
USE GLYCOL ONLY WITH DOUBLEWALLED
HEAT
EXCHANGER
MODELS. Glycol is a hazardous substance. To avoid
seepage or leakage of glycol to surfaces where children 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
children and animals should be protected from contact
with the unit.
2. Separate circulator. The recommended way to provide
adequate flow through the BOILER MATE™ heat
exchanger is to use a separate dedicated circulator with a
minimum flow rate of 4 gpm (10 feet of head minimum) and
maximum flow rate of 8 gpm. This option may be used
even though the heating system utilizes zone valves.
Do not connect the BOILER MATE™
domestic supply with baseboard or
other space heating units or elements. Any contaminants
in the baseboard units will contaminate the potable water
in the BOILER MATE™ and also adversely affect its
performance.
j All installations require a low-water cut-off or automatic
fill valve on your boiler system to reduce the risk of
boiler water loss.
j Steam boiler installations require a low-water cut-off
which is also required by most codes.
j Installation of a vacuum breaker is required to prevent
j Wiring Options. Select either a Non-Priority or Priority
damage to the BOILER MATE™ when drained.
System:
Two options are available when wiring the controls of the
BOILER MATE™ in the space heating system (boiler and
distribution elements).
1. Non-Priority System - The controls of the BOILER
MATE™ must be wired as a separate heating zone with
a standard zone valve or a separate circulator
dedicated to the BOILER MATE™ "zone".
NOTICE: In this non-priority option, the BOILER MATE™ will
be supplied just as another zone. This means that if all space
heating zones call for hot boiler water at the same time, the
BOILER MATE™ 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.
-4-
3. REQUIRED COMPONENTS AND
ACCESSORIES CHECKLIST
TD-7Z, TD-41Z, TD-7ZDW, TD-41ZDW
COMPONENTS CHECKLIST
The following is a checklist of components required for proper installation of these
BOILER MATE™ models, both Priority and Non-Priority:
A. Separate circulator
• 1 each - circulator (4-8 gpm)
• 1 each - positive shut-off weighted check valve
B. Use of heating system zone circulator
• 1 each - zone valve
C. Also Required:
• 4 each - unions
• 4 each - shut off valve
• 1 each - vacuum breaker
• 1 each - T & P relief valve (included)
• 1 each - A THERM-X-TROL® expansion tank - REQUIRED IF a Back flow preventer, check
valve or pressure reducing valve is installed anywhere between the BOILER MATE™ and
the city main.
• As needed - pipe dope or Teflon tape
• Do not forget an EXTROL® and thermal expansion - an expansion tank is required on the boiler
side of your system.
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® expansion tank and the boiler
temperatures are being changed, resize the EXTROL® expansion tank.
-5-
4. INSTALLATION INSTRUCTIONS FOR
FORCED HOT WATER, CLOSED HYDRONIC HEATING SYSTEMS
A. General Installation Requirements
Clearance From Combustible Surfaces
LEFT SIDE ...........10"
RIGHT SIDE.........10"
TOP......................30"
1. Do not "short circuit" the boiler
Do not connect boiler supply and return lines to the same
section or in the same flow circuit in a boiler, because the
boiler water returning from the BOILER MATE™ will "short
circuit" and exit the boiler too cold for proper heat transfer.
Recommended Clearance for Servicing
LEFT ....................10"
RIGHT..................10"
FRONT.................30"
2. Avoid high flow domestic water
recirculating loops
If a recirculating loop is necessary consult applicable Code
requirements. A flow of no more than 1/2 gpm is all that is
generally needed for temperature maintenance at the furthest
hot water fixture. Any flow greater than 1/2 gpm will result in
excessive heat loss and reduction in performance.
3. Locating Unit
Do not locate this product where
leaking and flooding could cause
damage to surrounding property.
REAR .....................1"
FLOOR ..................0"
FRONT ..................1"
HEAD ROOM ........30"
REAR .....................1"
4. Instructions for reversing unit:
The unit is designed to be reversible, i.e. depending on the
particular installation area, the BOILER MATE™ can be
rotated 180° for easier connection to the boiler and cold
water supply. All units are shipped "left-handed" with all
connections (boiler, cold water supply) on the left side of
the unit. If, for ease of installation, it is necessary to have
the connections on the right, the following steps should be
taken:
1. Carefully remove the front panel (remove top screw
and unhook from stand).
2. Move the access panel/electronic control assembly to the opposite side of the BOILER MATE™.
3. Remove the ground screw from the BOILER
MATE™ stand and save.
4. Proceed with electrical installation
5. Reassemble the access panel/electronic control to
the BOILER MATE™.
6. Confirm that the temperature sensor is firmly
inserted into the thermostat well.
7. Proceed with the installation.
The BOILER MATE™ should be located in an area where
water leakage from the tank or connections will not result
in damage to areas adjacent to the application or to lower
floors of the structure. When such a location cannot be
avoided, a suitable drain pan must be installed. The pan
must be connected to a drain. The installation location for
this unit should also be chosen to comply with the following required and recommended dimensions for clearance
and accessibility:
Clearance from Combustible Surfaces
This unit is design certified by the C.S.A. for installation on
combustible flooring and in alcoves, closets, etc. The minimum clearance dimensions from combustible material is
as follows: (See dimensions given facing units)
HEATING ZONES
TYPICAL INSTALLATION
ZONE VALVES
CONTROLLED BY
THERMOSTAT
SHUT-OFF
VAL VE
DOMESTIC
COLDWA
SUPPLY
PRV
SHUT-OFF
VAL VE
THERM-X-TR
TER
®
OL
SHUT-OFF
VAL VE
BOILER
SUPPLY
DOMESTIC
T
HO W
BOILER
MATE™
CIRCULATOR
ATE R
VA
C UM
BREAKER
HEATING
SYSTEM
RETURN
THERMAL
LOP
BOILER
RETURN
W
BLO
RELIEFVAL
-DW
O NTUBE
VE
BOILER
HEATING
CIRCULATOR
DRAIN
VA
L VE
FLW
O CHEK
VA
L VE
DRAL
AINV
-6-
VE
FIGURE 1
B. PIPING
BOILER SUPPLY
COLD
WATER
SUPPLY
PIPING SHOULD BE ACCOMPLISHED WITH UNIONS.
Step 1 - Locate the BOILER MATE™ near boiler.
BOILER
RETURN
Step 2 - Connect the cold water piping.
a. Shut off the cold water supply at the main shut-off
valve.
b. Drain existing domestic water system. Open 1 or
more system faucets to prevent vacuum.
c. When the system is drained, for boilers that have an
external or internal tankless heater, disconnect the
tankless heater from the domestic hot water piping.
T&P
OUTLET
DOMESTIC
HOT WATER
OUTLET
EXTERNAL TANKLESS HEATERS
Disconnect all the lines to the boiler and plug the boiler tappings. Disconnect the external heater from the domestic system piping and discard appropriately.
INTERNAL TANKLESS COILS
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. (Figure 3)
FIGURE 2
d. Install a shut-off valve in the existing cold water line.
e. Run 3/4" or 1/2" tube and fittings from the city main,
as required, to the BOILER MATE™
PLUG HERE
f. If a backflow preventer, pressure reducing valve or
check valve is installed anywhere between the
BOILER MATE™ and the city main, install a properly
sized Therm-X-Trol® pre-pressurized diaphragm-type
thermal expansion tank. See the water supplier or
local plumbing inspector for more information
X
INTERNAL
TANKLESS
COILS
EXTERNAL
TANKLESS
HEATER
Step 3 - Connect domestic hot water piping Figure 5.
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 TANK PRESSURE MUST BE LIMITED TO 150
PSIG MAXIMUM BY THE INSTALLATION OF A
TEMPERATURE AND PRESSURE RELIEF VALVE
(INCLUDED).
FIGURE 3
DAMAGE TO THE UNIT AND
LEAKAGE CAN OCCUR IF A
VACUUM BREAKER IS NOT INSTALLED.
SCALDING HAZARD: A CHECK VALVE
MUST BE INSTALLED IN THE BOILER
RETURN LINE TO PREVENT GRAVITY FLOW THROUGH
THE HEAT EXCHANGER. THIS CAN CAUSE OVER HEATING
AND RESULT IN SERIOUS SCALDING.
a. Attach the blow-down tube from the T & P valve
outlet. Install the blow-down tube to within 6" of the
floor. The blow-down tube should be placed so that it
will discharge to a drain with adequate capacity. No
reducing couplings, valves, or any other type of
restriction is to be installed in this line. The blow-down
tube must be installed to allow free and complete
drainage of both the valve and the blow-down tube.
DO NOT PLUG
c. To minimize piping heat loss during non-draw periods,
a thermal trap can be installed in the hot water line as
shown in Figure 1.
Step 4 - Fill the BOILER MATE™.
a. Open a hot water faucet in the house to allow any air
in the BOILER MATE™ and in the piping to escape.
b. Open the shut-off valve in the cold water line.
c. Open the shut-off valve(s) in the hot water supply line.
d. When water discharges from the faucet, close it.
Check for system leaks and repair if necessary.
b. Install a union, shut-off valve and vacuum breaker on
the hot water outlet.
-7-
SEPARATE CIRCULATOR
Step 5 - Connect boiler supply pipe. Figure 1.
a. Shut off the cold water supply valve to the boiler, and
drain it using a hose attached to the drain valve at the
boiler.
I. BOILER MATE™ as Separate Zone - Non-Priority
A. Use of separate BOILER MATE™ ZONE CIRCULATOR
b. When the boiler system piping is drained, cut the
piping to accommodate the supply line tee. Install the
tee between the boiler supply outlet and any system
zone valve or flow check.
Step 1 - Disconnect electrical power.
a. Turn off the boiler service switch.
b. Turn off the safety switch (if separate from
the service switch).
c. Switch off the branch circuit breaker.
c. Connect the circulator flange and mount the
circulator to the boiler supply. Be sure the flow
arrow points towards the BOILER MATE™. Mount
the second flange to the circulator.
Step 2 - Remove electrical box cover on Thermostat.
Step 3 - Wire BOILER MATE™ using
Schematic #1 or #2.
a. Install BX connector.
b. Insert outside wiring to BOILER MATE™
through electrical conduit opening on
thermostat.
c. Complete exterior electrical wiring per
Schematic #1 or #2.
d. Connect a 3/4" NPTM to a 3/4" sweat adapter to the
second circulator flange.
e. Using short lengths of tubing, connect the 3/4"shutoff valve.
f. Run the 3/4"copper tubing with necessary fittings to
the point of connection to the boiler supply tee.
Step 6 - Connect boiler return pipe. Figure 1.
Step 4 - Turn boiler low-limit control (it is part of the
boiler control) to the off position.
a. Connect the 3/4" NPT, boiler return fitting and
connect the drain valve and union.
b. Sweat a short length of tubing to the adapter and
connect the weighted check valve with the flow
towards the boiler (preventing flow towards the
BOILER MATE™). Failure to do so will result in the
BOILER MATE™ overheating.
c. Run the 3/4" tubing and fittings as required to the
point of connection to the boiler return.
NOTE: This point must be between the boiler return
tapping and any system circulator(s). Failure to do so
will result in the BOILER MATE™ overheating.
Note: Some boilers require minimum setting of low limit.
SEPARATE CIRCULATOR
Step 7 - Refill the boiler system
a. Open the cold water supply valve to the boiler.
b. Check for system leaks.
c. Close the weighted check valve on the boiler return
piping of the BOILER MATE™
d. Open the drain valve on the boiler return line to
release entrapped system air.
e. Close the drain valve
f. Open the weighted check valve.
C. ELECTRICAL WIRING
All wiring must be in accordance with local codes, regulations,
and ordinances or, in the absence of such codes, the National
Electrical Code ANSI/NFPA No. 70, latest edition.
Step 5 - Adjust boiler high-limit control to the desired
setting. In most cases 180° F to 200° F
is acceptable.
Step 6 - Re-assemble electrical box cover.
The BOILER MATE™ thermostat can be used for either 24 or
120V AC. The thermostat is packaged separately and is installed
by sliding the capillary tube into the thermostat well.
Step 7 - Re-connect electrical power.
B.
First
hazard.
Electrocution
dis-connect all electrical power
before doing any electrical work.
Electrocution hazard. The BOILER
must
be
electrically
MATE™
grounded.
Use of only the heating system circulator.
When wiring a separate zone valve, follow all steps in 1A
except for Step 3c. Use Schematic #3(A, B or C)
depending upon the type of zone valve. (Zone valve
sizing per pg. 5)
II. BOILER MATE™ - Priority Wiring
Hot Water Before Space Heating
A. Use of separate BOILER MATE™ zone.
A DPDT relay is to be used. Refer to Schematic #4.
Electrical supply must come from the
boiler side of boiler’s emergency
shut-off switch in order to prevent
unsafe boiler operation.
Step 1 - Disconnect electrical power.
a. Turn off the boiler service switch.
b. Turn off the safety switch (if separate from
-8-
lowest temperature which satisfies your hot water needs. This will
also provide the lowest operating costs.
the service switch).
c. Switch off the branch circuit breaker.
In conjunction with a Consumer Product Safety Commission
recommendation, an initial setting of 120° F is recommended.
This may or may not be suitable for your needs. Check the
temperature at a hot water faucet soon after the burner has
completed the first heating. Adjust as needed. Note that
adjusting to a lower setting will not have an immediate effect. The
stored hot water will first have to be used. Additional checks of
the water temperature should follow completion of a cycle.
Further adjustments may be necessary as you use your BOILER
MATE™ and water piping system.
NOTE: VALVES FOR REDUCING POINT OF USE
TEMPERATURE BY MIXING COLD AND HOT WATER ARE
AVAILABLE. CONSULT A LICENSED PLUMBER OR THE
LOCAL PLUMBING AUTHORITY.
Step 2 - Remove electrical box cover.
Step 3 - Remove existing wire from boiler aquastat
terminal C1 and connect to terminal #2 on
DPDT relay.
Step 4 - Install wire from DPDT relay terminal #1 to boiler
aquastat terminal C1.
Step 5 - Connect terminals of 4 and 6 of DPDT relay "TT" terminals of boiler aquastat relay.
Step 6 - Connect BOILER MATE™ thermostat to L1,
BOILER MATE™ and DPDT relay as shown
in Schematic #4.
Step 7 - Connect L2 to BOILER MATE™ circulator
and DPDT relay as shown in Schematic #4.
ZONE VALVES - SCHEMATIC 3
B. Use only the heating system circulator.
When wiring a separate, full-flow 3-way zone valve, follow
steps in 1B. above.
Note: Priority comes from the valve operation and not the
wiring.
SEPARATE CIRCULATOR
3-WIRE ZONE VALVES
D. POST-INSTALLATION and
START-UP CHECKLIST
4-WIRE ZONE VALVES
After the BOILER MATE™ has been plumbed and wired, it is now
ready to be set for automatic operation. Turn on the boiler and
safety switches.
PRIORITY W/CIRCULATORS - SCHEMATIC 4
TEMPERATURE ADJUSTMENT
PAINFUL SCALDING WITH POSSIBLE
SERIOUS AND PERMANENT INJURY
CAN OCCUR IF THE TEMPERATURE IS SET TOO HIGH OR
THE THERMOSTAT IS NOT FUNCTIONING PROPERLY.
The thermostat controls the maximum water temperature in the
BOILER MATE™. If set too high, the resulting hot water can
cause painful scalding with possible serious and permanent
injury. The temperature at which this occurs varies with a
person’s age and the length of time in contact with the water.
The slower response time of infants, aged or handicapped
persons increases the hazard to them.
It is recommended that the temperature control be set for the
-9-
-10-
6. OPERATION/MAINTENANCE.
FOR FORCED HOT WATER, CLOSED HYDRONIC HEATING SYSTEMS
AND LOW PRESSURE STEAM BOILER.
The BOILER MATE™ is intended to provide a tank service life of
many years. Components, however, may be subject to failures
that require service. Failure to use the correct procedures or parts
in these circumstances may make the unit unsafe.
Do not over-drain the tank. Improper
thermostatic control could result
during Step 6 and lead to damage to the BOILER MATE™.
6. Using a funnel, pour one gallon of commercial
phosphoric acid solution (commercial icemaker
cleaning solution) into the water tank through the top
opening. Be sure that the manufacturer’s directions,
cautions, and warning on the container are followed:
• DO NOT OPEN DOWN-STREAM FIXTURE IF YOU
HAVE LOOSENED THE TOP CONNECTIONS.
• DO NOT OVER-DRAIN THE TANK - THE HEAT
EXCHANGER MUST REMAIN COVERED BY WATER TO
AVOID DAMAGE TO THE LINER.
7. Set the temperature control to its highest setting and
operate the system 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 it to its lowest setting to stop boiler operation.
The owner should arrange to have the following inspections
and simple maintenance procedures done at the
frequencies suggested.
a. Domestic Water Piping - Yearly Visual Inspection Check
all piping for a signs of leakage at joints, unions and shutoff valves. Remedy as needed.
8. Allow heated solution to set in tank for 30 minutes.
then drain tank completely using fitting and hose, as
required, to reach a floor drain.
b. Boiler Water Piping - yearly Visual Inspection Check all
piping for signs of leakage at joints, unions and shut-off
valves. remedy as needed.
9. Fill water tank with fresh, cold, conditioned water and
drain completely at least two time to flush all
phosphoric acid mixture from the tank.
c. T & P Relief Valve - Yearly Inspection
10.Reinstall the temperature pressure relief valve, being
sure the (1) the temperature pressure relief valve
temperature probe reaches into the top portion of the
tank and (2) the top half union fitting is firmly in place.
d. Sediment - Monthly Inspection - depending on water
conditions
Depending on water conditions, a varying amount of
sediment may collect in the tank. This is normal. Levels
requiring service are indicated by a small temperature
difference in the supply and return lines. (See also "Scale"
below.) Repeated flushing usually clears such material. As
a preventive measure, each month water should be drawn
from the tank at the drain valve until it runs clear.
e. Scale - Monthly Inspection
A small temperature difference between the water entering
and leaving the coil may indicate a scale build-up. A water
softener will prevent this problem. (See also "Sediment"
above.) Repeated flushing should also resolve the
problem. If not, proceed as follows:
1. To avoid water damage to nearby areas in subsequent
steps, shut off the cold water supply to the BOILER
MATE™.
11.Open the cold water supply and fill the tank with
water. Then purge air from lines and tank by operating
hot and cold water faucets in the house.
12.Return the Smart Control™ to the setting noted in Step
2 and verify it is working properly as described on
page 17.
As an alternative to the above, the heat exchanger may be
removed from the BOILER MATE™, cleaned, and reinstalled (with
a new gasket); or, in some cases, a simple high velocity washing
by water from a wand may be used in place of Steps 5-9. The
chemical cleaning process, however, is the most effective if done
properly.
2. Make a note of the temperature control setting on the
BOILER MATE™, then turn the unit off by depressing
the key switch on the Smart Control™ until the unit
reads "OFF".
3. Relieve the water pressure in the tank by opening a
hot water faucet. This will reduce the risk of scalding
injury.
4. Remove the relief valve from the top of the BOILER
MATE™, taking care to avoid contact with the hot
water which may drain out of the lines leading to the
domestic uses.
5. Drain the BOILER MATE™ until the water within the
tank is even with the top of the heat exchanger roughly 15 gallons for 41-gallon units and 5 gallons for
26-gallon units.
-11-
7. REPLACEMENT PARTS
RESIDENTIAL
BOILER MATE™ CLASSIC
(TD-7Z and TD-41Z)
4
ELECTROCUTION HAZARD.
THE BOILER MATE™ MUST
BE ELECTRICALLY GROUNDED.
3
2
NOTES:
1. THE BOILER MATE™ MUST BE ELECTRICALLY GROUNDED AND INSTALLED IN
ACCORDANCE WITH LOCAL CODES, OR IN
THE ABSENCE OF LOCAL CODES, WITH
THE NATIONAL ELECTRIC CODE.
5
1
2. HEAT EXCHANGER PACKAGE INCLUDE
ITEMS 5-11
3. TORQUE NUTS 12 TO 14 FT. LBS.
FAILURE TO USE THE
CORRECT REPLACEMENT
PARTS MAY MAKE YOUR UNIT UNSAFE.
6
DESCRIPTION
PART
NUMBER
1
AQUASTAT CONTROL
2704-093
2
HEAT EXCHANGER - COMPLETE
2700-5004
3
GASKET ONLY
2704-403
4
THERMISTOR DRY WELL
2700-924
5
TOP COVER
20-0001
6
DRAIN VALVE
9340-087
ITEM
-12-
8. TROUBLE SHOOTING CHECKLIST
PROBLEM
1. No hot water at faucet.
CAUSE
SOLUTION
1.Boiler does not operate.
1.a. Press reset button on boiler.
b.Check main cut-off switch.
c. Check fuse.
2.Circulator does not operate.
2.a. Check power supply.
b.Check shaft coupling.
c. Check impeller for locking.
3.Improper BOILER MATE™
3.Set BOILER MATE™ temperature to
a higher setting. Call boiler service.
setting or calibration.
4.Zone valve does not open.
4.Check power supply.
5.Electrical problems (relay, wiring,
5.a. Check fuse and replace.
fuse, low voltage, brown-outs, etc.)
b.Check circuit breaker and
reset (if applicable).
c. Check power supply.
d.Low voltage or brown-out conditions
can make the boiler control inoperative;
engage the boiler reset button.
6.BOILER MATE™ scale
build-up.
6.If boiler, circulator, and BOILER MATE™
temperature controls are operating
satisfactorily, the BOILER MATE™ coil
may have scale coating. Remove coil and
clean or keep coil in tank and treat with
a phosphoric acid product (e.g. NuCalgon 1-800-554-5499) (Refer to page 20)
7.Clogged filter (if used) or clogged
7.Clean and replace filter.
strainer in steam boiler systems.
2. Insufficient or runs out of
hot water at faucet.
1.BOILER MATE™
1.Set BOILER MATE™
temperature setting too low.
2.Undersized boiler with no
temperature control to a higher setting.
2.Rewire for priority.
priority to domestic hot water.
3.Peak use of hot water is greater
than BOILER MATE™ storage.
4.BOILER MATE™ scale
3.Determine peak usage and compare tank
volume.
4.Clean coil according to instructions.
build-up.
5.Faulty BOILER MATE™
5.Replace control.
temperature control.
3. Water at faucet too hot.
1.BOILER MATE™ temperature is
set too high.
4. Boiler cycles more than 5
times per day in summer.
Boiler runs for longer
Periods of time .
1.Lower BOILER MATE™
temperature.
2.Improper system plumbing.
2.Compare plumbing to installation guide.
3.Improper system wiring.
3.Compare wiring to installation guide.
4.Probe out of thermostat well.
4.Check to make sure Probe is properly inserted,
see Figure 2 Page 8.
1.Excessive demand.
1.Reduce demand or consider larger
BOILER MATE™.
2.Damaged or broken BOILER MATE™
temperature control.
2.Replace BOILER MATE™
temperature control.
3.Boiler hi-limit set too low.
3.Increase boiler hi-limit.
4.BOILER MATE™ scale build-up.
4.Clean coil according to instructions.
-13-
9. SERVICE RECORD
DATE
SERVICE PERFORMED
COMMENTS
-14-
CONTRACTOR
AMTROL® BOILERMATE™ CLASSIC AND TOP-DOWN™ LIMITED PRODUCT WARRANTY
This Warranty cannot be transferred - it is extended only to the original Purchaser or First User of the Product. By accepting and keeping this Product you
agree to all of the warranty terms and limitations of liability described below.
IMPORTANT WARNING: READ CAREFULLY THE INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS MANUAL (“MANUAL”) to avoid
serious personal injury and/or property damage and to ensure safe use and proper care of this product.
Mail Your Product Registration Card Within 30 Days of Purchase to Ensure Your Warranty Coverage or Proof of Purchase Will Be Required for All Warranty
Claims.
LIMITED LIFETIME WARRANTY* Tank Assembly and Heat Exchanger (To Original Product Owner, Single Family Residence)
WH and TD Model Numbers Covered: WH-7Z, WH7-ZDW, WH7-P, WH7-L, WH7-LDW, WH-9L, WH-9LDW, TD-7L, TD-7Z,TD-7P, TD-7LDW, TD-7ZDW
LIMITED FIVE YEAR COMMERCIAL WARRANTY**
Model Numbers Covered: WH7C, WH7CDW
LIMITED FIVE YEAR TRANSFERRABLE WARRANTY**
Model Numbers Covered: WH-41Z, WH-41L, TD-41L, TD-41Z, TD-41LDW and TD-41ZDW only
Warranty for these models only runs from date of manufacture and are transferable
*FOR AS LONG AS YOU OWN AND LIVE IN YOUR SINGLE FAMILY HOME, this Warranty covers the tank assembly and heat exchanger, if you are the first
user or original owner of this BoilerMate™ Classic and Top-Down™ and purchased it for single family home use – subject to all of the conditions, limitations and exclusions listed below. Purchasers who buy the BoilerMate™ Classic and Top-Down™ for other purposes, and other component parts are subject
to more limited warranties and you should read all of the terms included in this form to make sure you understand your Warranty.
LIMITED WARRANTY ON BOILERMATE™ CLASSIC AND TOP-DOWN™ TANK ASSEMBLY AND HEAT EXCHANGER
AMTROL Inc. (“AMTROL”) warrants that at the time of manufacture, the BoilerMate™ Classic and Top-Down™ heat exchanger and tank assembly shall be free
from defects in material and workmanship for one of two time periods as follows:
Period 1 – Single Home Use. If you are the first user or original owner of the BoilerMate™, for as long as you own and occupy the single-family home
in which the BoilerMate™ Classic and Top-Down™ has been properly installed.
Period 2 - ** Commercial and Other Uses. For five years from the date of purchase if you are the first user or original owner first using the new BoilerMate™
Classic and Top-Down™ (except for the model numbers listed above that are transferable), and you are not a homeowner-purchaser as described in Period 1
(for example, if you purchased the Product for re-sale, or a commercial, industrial, non-residential, multi-unit or rental property application).
LIMITED ONE YEAR WARRANTY ON ALL BOILERMATE™ CLASSIC AND TOP-DOWN™ COMPONENT PARTS
AMTROL warrants to the first user or original owner using the new BoilerMate™, that at the time of manufacture, except for the tank assembly and the heat
exchanger referenced above, all other AMTROL supplied components or parts of the BoilerMate™ are warranted to be free from defects in material or
workmanship for one year from the date of purchase.
What AMTROL Will Do If You Have a Covered Warranty Claim
In the event of a breach of the foregoing warranty, AMTROL will at its option either make repairs to correct any defect in material or workmanship or supply
and ship either new or used replacement parts or products. AMTROL will not accept any claims for labor, property damage or other costs.
What This Warranty Does Not Cover - Exclusions and Limitations
This Warranty does not cover any claim unless it was caused by a defect in material or workmanship during the warranty periods specified above. In addition,
this Warranty shall not apply:
• if the Product is not correctly installed, operated, repaired or maintained as described in the Manual provided with the Product;
• to any failure or malfunction resulting from abuse (including freezing); improper or negligent: handling, shipping (by anyone other than AMTROL), storage,
use, operation, accident; or alteration, lightning, flood or any other environmental condition;
• to any failure or problem resulting from the use of the Product for any purpose other than those specified in the accompanying Manual or alteration of any
part of the product;
• if the Product is used anywhere except the United States, its territories or possessions, or Canada;
• this Warranty does not cover labor costs, shipping charges, service charges, delivery expenses, administrative fees or any costs incurred in removing or
reinstalling the Product;
• this Warranty does not cover any claims submitted to AMTROL or an AMTROL-authorized distributor or retailer more than 30 days after expiration of the
applicable warranty time period described in this Warranty;
• this Warranty also does not cover repair or replacement costs not authorized in advance by AMTROL.
• if the unit has not always been operated within the factory calibrated temperature limits, and at a water pressure not exceeding 150 psi or it is subjected to
chlorine concentrations in excess of 5 ppm;
Additional Warranty Limitations
ALL IMPLIED WARRANTIES, INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE
SPECIFICALLY DISCLAIMED. Some states do not allow limitations on how long an implied Warranty lasts, so the above limitation may not apply to you.
Limitations of Remedies
THE REMEDIES CONTAINED IN THIS WARRANTY ARE THE PURCHASER’S OR FIRST USER’S EXCLUSIVE REMEDIES. IN NO CIRCUMSTANCES
WILL AMTROL BE LIABLE FOR MORE THAN, AND PURCHASER-FIRST USER’S REMEDIES SHALL NOT EXCEED, THE PRICE PAID FOR THE
PRODUCT. IN NO CASE SHALL AMTROL BE LIABLE FOR ANY SPECIAL, INDIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES, WHETHER
RESULTING FROM NONDELIVERY OR FROM THE USE, MISUSE, OR INABILITY TO USE THE PRODUCT OR FROM DEFECTS IN THE PRODUCT
OR FROM AMTROL’S OWN NEGLIGENCE OR OTHER TORT.This exclusion applies regardless of whether such damages are sought for breach of warranty,
breach of contract, negligence, strict liability, in tort or under any other legal theory. Such damages include, but are not limited to, inconvenience, loss or
damage to property, mold, loss of profits, loss of savings or revenue, loss of use of the Products or any associated equipment, facilities, buildings or services,
downtime, and the claims of third parties including customers. Some states do not allow the exclusion or the limitation of incidental or consequential damages, so
the above limitation or exclusion may not apply to you.
What To Do If You Have a Problem Covered By This Warranty
Any covered Warranty service must be authorized by AMTROL. Contact the person from whom you purchased the Product, who must receive authorization
from an AMTROL distributor or AMTROL. If you do not receive a prompt response, call AMTROL directly at 401-535-1216. Notice of a Warranty claim should
be submitted by the authorized distributor to AMTROL at the following address:
AMTROL Inc., Warranty Claim Dept.
1400 Division Rd., West Warwick, RI 02893
Before AMTROL determines to provide any replacement part or Product, it may as a pre-condition to making such a determination require that the warranty
claimant ship the Product, postage prepaid to an authorized AMTROL distributor, or to AMTROL and provide proof of purchase evidenced by the original
sales receipt or Product registration.
Replacement Product Warranty
In case of replacement of a Product or any component part, AMTROL reserves the right to make changes in the design, construction, or material of the
substitute components or products, which shall be subject to all of the terms and limitations of this Warranty, except that the applicable warranty periods shall
be reduced by the amount of time the warranty claimant owned the product prior to submitting notification of the warranty claim.
-15-
West Warwick, Rhode Island 02893
Part #: 9040-628 REV B (7/04)
-16-
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