Installation manual | Amtrol HM-41Z Water Heater User Manual

INSTALLATION & OPERATION INSTRUCTIONS
HYDROMAX™
INDIRECT-FIRED WATER HEATERS
1400 Division Road, West Warwick, RI 02893
T: 401.884.6300
F: 401.885.2567
www.amtrol.com
PLEASE READ THE FOLLOWING INSTRUCTIONS CAREFULLY
INSTALLER: LEAVE THIS MANUAL WITH THE OWNER
Models Covered:
HM-41Z & HM-80Z (Mechanical Control)
HM-41L & HM-80L (Ener-G-NET™ Digital Control)
IMPORTANT GENERAL SAFETY INFORMATION - ADDITIONAL SPECIFIC SAFETY ALERTS APPEAR IN THE
FOLLOWING INSTRUCTIONS.
DO NOT LIFT OR CARRY WATER HEATER BY THE TOP COVER. WATER HEATER DAMAGE OR PERSONAL
INJURY MAY OCCUR IF THE COVER BECOMES DETACHED.
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.
9040-694 (10/11)
1. Table Of Contents
2. Pre-Installation Checklist................................................ 2
7. Mechanical Aquastat Wiring........................................... 8
3. Required Components and Accessories Checklist........ 3
8. Startup Procedure.......................................................... 9
4.HYDROMAX™ Plumbing................................................ 4
9.Troubleshooting.............................................................. 9
5.Ener-G-NET™ Wiring................................................... 5-6
10.General Safety Information.......................................... 10
6.Ener-G-NET™ Setup & Adjustment................................ 7
11.Replacement Parts....................................................... 11
2. Pre-Installation Checklist
IMPORTANT STEPS AND DECISIONS REQUIRED BEFORE INSTALLATION
❑ 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.
❑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.
❑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 water heater or the rest of
your plumbing system.
USE
GLYCOL
ONLY
WITH
DOUBLE-WALLED HEAT EXCHANGER
MODELS. Glycol is a poisonous 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.
NOTICE: In this non-priority option, the water heater 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
water heater may not be supplied with enough hot boiler water
to “recover” adequately. The delivery of domestic hot water will
be diminished. In many, but not all cases, this is not a problem
because the routine oversizing of boiler output is adequate for
both loads.
2.Priority System - Under this wiring option the water heater
will be supplied before space heating.
In limited circumstances, space
heating can be lost in the home in this
priority mode. Any demand for space heating is postponed
until the water heater 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.
❑ Select Circulator versus Zone Valve
The flow of hot boiler water to the water heater can be
controlled with either a motorized zone valve or a circulator.
1. Separate circulator. The recommended way to provide
adequate flow through the water heater heat exchanger is
to use a separate dedicated circulator. This option may be
used even though the heating system utilizes zone valves.
Do not connect the water heater domestic
supply with baseboard or other space
heating units or elements. Any contaminants in the
baseboard units will contaminate the potable water in the
water heater and also adversely affect its performance.
2. Zone valve If a zone valve is to be used, a flow rate of 3
to 5 gpm with all zones in use is required. A full-port zone
valve should be used.
❑Wiring Options. Select either a Non-Priority or Priority
System:
Two options are available when wiring the controls of
the water heater in the space heating system (boiler and
distribution elements).
❑ All installations require a low-water cut-off or automatic fill valve on
your boiler system to reduce the risk of boiler water loss.
❑ Steam boiler installations require a low-water cut-off which is also
required by most codes.
❑ Installation of a vacuum breaker is required to prevent damage to
the water heater when drained. There must be no valves installed
between the vacuum breaker and water heater.
1.Non-Priority System - The controls of the water heater
must be wired as a separate heating zone with a standard
zone valve or a separate circulator dedicated to the water
heater “zone”.
-2-
3. Required Components And
Accessories Checklist
MODEL
CIRCULATOR
ZONE VALVE
PERFORMANCE
SHUTOFF
VALVES
RELIEF VALVE
THERMAL
EXPANSION
TANK
HM-41
5 GPM @ 7 FT
3/4” Full Port
4
Included
2.0 Gallon
HM-80
5 GPM @ 7 FT
3/4” Full Port
4
Included
4.4 Gallon
If a steel hydropneumatic tank is in place, replace it with a properly sized diaphragm
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 existing expansion tank and the boiler temperatures
are being changed, resize the existing diaphragm expansion tank.
Use care when using a torch near the top cover and heat exchanger plate. It is recommended
that the front half be removed prior to soldering to avoid potential damage.
HYDROMAX™ Components
Boiler Return
2 Piece Cover Removal and Installation
Boiler Supply
Hot Water
Outlet
Cold Water
Inlet
Retaining Screws (2)
Heat Trap
Removing Front Half:
Depress both tab buttons to
detach one side at a time.
Heat Exchanger Pressure Loss
Installing Front Half:
Align bottom groove of cover
onto metal retaining ring.
Beginning with one side,
align pin and push until both
tabs lock. Repeat for other
side, ensuring all tabs are
fully engaged.
Head Loss (Feet)
15
Removing Entire Cover:
Remove front half, loosen
both retaining screws and
remove rear half.
10
5
0
0
2
4
6
8
Flow (Gallons Per Minute)
-3-
Tab Buttons (4)
4. HYDROMAX™ Plumbing
DOMESTIC WATER PIPING
Do not drill, puncture or otherwise
penetrate the steel outer tank shell.
Do not screw pipe hangers or other hardware into the
exterior of the tank.
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. 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, a properly sized thermal expansion
tank is required and should be installed in accordance with the
product installation manual.
Note: If a water heater is installed in a closed water supply system,
such as one having a back-flow preventer in the cold water supply,
means shall be provided to control thermal expansion. Contact
the water supplier or local plumbing inspector on how to control
this situation.
Note: If an external electrical source is utilized, the appliance, when
installed,must be electrically grounded in accordance with local
codes or, in the absence of local codes, with the National Electrical
Code, ANSI/NFPA 70.
Note: The thermostat is adjusted to 120° F, when shipped from
the factory.
4. Install the 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
1. Plumb the circulator or zone valve 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
water heater temperature.
4. After completing the boiler piping, slowly open the boiler fill
valve and pressurize the water heater loop. Check for leaks
and repair as necessary. Proceed to the appropriate wiring
section in this manual.
EXPLOSION HAZARD. Do not install to
a high pressure steam boiler (greater
than 15 psig). An explosion could occur.
Clearance From Combustible Surfaces
LEFT SIDE . . . . . . . . . . . 1"
REAR . . . . . . . . . . . . . . . 1"
RIGHT SIDE . . . . . . . . . . 1"
FLOOR . . . . . . . . . . . . . . 0"
TOP . . . . . . . . . . . . . . . . . 9"
FRONT . . . . . . . . . . . . . . 1"
BLOWDOWN
TUBE
Recommended Clearance for Servicing
LEFT . . . . . . . . . . . . . . . 12"
HEAD ROOM . . . . . . 36"
RIGHT . . . . . . . . . . . . . . 12"
REAR . . . . . . . . . . . . . 1"
FRONT . . . . . . . . . . . . . 30"
WIRING AND AQUASTAT
ON FRONT CAP HALF
BOILER SUPPLY
COLD WATER
SUPPLY
TEMPERATURE
SENSOR WELL
HOT WATER
OUTLET
BOILER RETURN
TOP VIEW
FROM FRONT
PIPING USING ZONE VALVE
DRAIN
REAR VIEW
(FOR CLARITY)
-4-
5. Ener-G-NET™ Wiring
Ener-G-NET incorporates all of the temperature sensing and control necessary for
HYDROMAX™ operation. Built-in switching relays may be wired to operate the boiler
control and circulator pump or zone valve. The diagram below illustrates these internal
switching functions.
Examples of common wiring scenarios are provided on the following page.
Front Panel
Normally Open
Close on call for hot water
Post-Purge function
{
Control
Screws (4)
Normally Open
Close on call for hot water
ORANGE
ORANGE
{
Wiring Cover
Conduit Holes (3)
Ground Screw
Normally Closed
Open on call for hot water
Priority function
BLUE
BLUE
{
Constant 24VAC or 120VAC
VIOLET
VIOLET
{
WHITE
Power In
BLACK
After wiring is complete, insert the white temperature sensor (thermistor) plug into the receptacle at the base of the digital 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 digital control temperature set point. This is why it is important to install
the correct sensor into the digital control. See Page 2 for information regarding the selection of a circulator or zone valve.
Temperature
Sensor Plug
Water
Sensor Plug
Water
Sensor
NOTE: This sensor should not be the primary means of water detection. US PATENT NO: 7,671,754 and other patents pending.
NOTE: Line-voltage and safety-circuit wiring which is external to the water heater jacket when all panels are in place, and which
is part of the appliance, shall be protected by metal conduit, metal-clad cable or raceways. “Power Limited Circuit Cable” needed
not be provided with the protection specified above if it is securely fastened to the appliance jacket and follows the contour of the
appliance jacket. Thermoelectric wiring shall be exempt from this provision.
NOTE: Strain relief shall be provided for all conductors leaving an enclosure. For low-voltage wiring, strain relief at the point of exit
from an enclosure is not necessary if, by wire location or support, protection is provided against accidental strain.
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 insert a coin
between the two electrodes and listen for audible alarm.
-5-
Ener-G-NET™ Wiring
Common wiring diagrams are shown below. Select the appropriate diagram for the application. Diagrams are popular examples
only. If your application is not shown, contact Amtrol Technical Support at 401.535.1216. NOTE: Ensure the Ener-G-NET installation
is within the following application and operating parameters:
• Ambient temperature from 38° 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, 1/4hp inductive @ 120VAC.
• Space heating load rating up to 8A @ 120VAC.
Oil Burner Controls
Triple-Aquastat
B
C1
C2
BOILERMATE
CIRCULATOR
HEATING
CIRCULATOR
®
BOILERMATE
CIRCULATOR
C2
HEATING
CIRCULATOR
®
VIOLET
R
BLUE
L1
PRIORITY
VIOLET
ORANGE
L2
PUMP
BLUE
ORANGE
BURNER
BLACK
C1
B
C2
POWER
WHITE
BLUE
VIOLET
PRIORITY
VIOLET
L1
PUMP
BLUE
L2
BURNER
ORANGE
BLACK
C1
ZR
POWER
WHITE
VIOLET
BLUE
PRIORITY
VIOLET
ORANGE
L1
PUMP
BLUE
BLACK
L2
BURNER
ORANGE
WHITE
POWER
High Limit (B Terminal)
ORANGE
ZR Input Terminal
BOILERMATE®
CIRCULATOR
HEATING
CIRCULATOR
Gas Valve Controls
HEATING
CIRCULATOR
B
C1
C2
BOILERMATE®
CIRCULATOR
C2
BOILERMATE®
CIRCULATOR
HEATING
CIRCULATOR
HEATING
CIRCULATOR
Other Applications
BOILERMATE®
CIRCULATOR
L2
L1
X
X
L2
VIOLET
PRIORITY
VIOLET
BLUE
PUMP
BLUE
ORANGE
ORANGE
BURNER
24VAC
MOTOR
L1
TRANSFORMER
DHW ZONE
L2
X
BLACK
POWER
WHITE
VIOLET
PRIORITY
VIOLET
BLUE
BLUE
ORANGE
PUMP
24 OR 120VAC
DHW ZONE
TO BOILER
BURNER
ORANGE
POWER
BLACK
VIOLET
BLUE
PRIORITY
VIOLET
PUMP
BLUE
ORANGE
BURNER
ORANGE
BLACK
WHITE
POWER
4-Wire Zone Valve
Multi-Zone Control: No Post Purge
WHITE
Multi-Zone Control: Using Post Purge
X
TO BOILER
BOILERMATE®
CIRCULATOR
OR ZONE VALVE
-6-
VIOLET
B2
VIOLET
L1
PRIORITY
BLUE
L2
PUMP
BLUE
ORANGE
BURNER
ORANGE
VIOLET
C1
POWER
BLACK
W
PRIORITY
WHITE
B
Z
PUMP
VIOLET
B2
Self-Generating
BLUE
L1
ORANGE
L2
C2
BOILERMATE®
CIRCULATOR
BURNER
ORANGE
C1
B
W
POWER
BLACK
VIOLET
VIOLET
BLUE
PRIORITY
WHITE
Z
BLUE
L1
PUMP
ORANGE
BLACK
L2
BURNER
ORANGE
WHITE
POWER
Millivolt
BLUE
24 Volt
L1
ZONE VALVE
END
SWITCH
6. Ener-G-NET™ Control Setup & Adjustment
Mode
Indicators
User
Modes
LED
Display
Installer
Settings
Ener-G-NET features two distinct programming areas: User Modes and
Installer Settings. User Modes consist of three end-user functional
modes, while Installer Settings are primarily accessed upon initial setup
to specify critical operating parameters. Ener-G-NET factory defaults
allow traditional operation suitable for most homes. To optimize the
control setup, reference the tables below.
Temperature settings above 120° F can create a
scald hazard.
User Modes are used to select from three distinct operational modes. To select, press the green MODE button and press again to cycle through the three
available modes. A green dot illuminates to display the current mode.
User Mode
Code
Description
Standard
Traditional operation within preset temperature differential using a low and high limit.
Efficiency
On-Demand sensing reduces fuel consumption by limiting boiler operation during idle periods.
Vacation
Reduced temperature setting minimizes boiler operation during anticipaated periods of non-use.
Installer Settings are used to adjust functional operating parameters. To adjust, press and hold the SET button until the Temperature setting appears.
Cycle through settings by depressing the SET button and using the ▼ and ▲ buttons to change the settings.
Setting
Code
Description
Range
Temperature
Domestic hot water setpoint. Default is 120°F
Differential
Domestic hot water temperature drop before call for heat. Default is 10°F.
Post-Purge
Early boiler shutoff prior to hot water setpoint. Circulator runs until setpoint. Default is 0°F.
0,4,8**
Priority
Temporarily cancels space heat to maxmize available energy for hot water. Default is 'n'.
y/n
Capacity
Water heater capacity; select appropriate size for proper operation. Default is 41 Gallons.
26,41,60,80,120
BTU Transfer
Real-time BTU transfer estimate in 1000 BTU/Hr increments. Diagnostic readout only.
90-150
5,10*
0-199MBH/Hr
*Available in Standard Mode only.
**Available only when Differential setting is 10.
Diagnostic Error Codes display a visual indicator and sound an alarm if a fault is detected. Codes clear automatically when corrected or can be reset by
interrupting power to the control for 5 seconds. To silence an alarm, depress the ▼ on the keypad.
Error
Code
Description
Potential Causes***
Sensor unplugged
Sensor damaged
Temp Sensor
Temperature sensor (thermistor) fault.
Overheating
Domestic hot water temperature has exceeded maximum setpoint.
Slow Heating
Unit has taken over 60 minutes to reach hot water setpoint or cannot reach setpoint.
Water Alarm
Standing water detected.
Error in boiler plumbing
Zone valve stuck open
Leak in sensor well
Faulty equipment
Fouled heat exchanger
No fuel
Standing water
***See Troubleshooting section for additional information
Operating Indicators are used to display operational and functional status. Water sensor temperature may be shown for 30 seconds by pressing
the ▲ button.
Indicator
Code
Description
Startup Test
Displayed briefly during intial powerup to test LED display segments.
Idle
Static numeric [setpoint] readout (factory default shown) indicates domestic hot water setpoint.
Heating
Alternating On and [Setpoint] is displayed during a heating cycle while the circulator pump contacts are closed.
-7-
7. Mechanical Aquastat Wiring Diagrams
Common wiring diagrams are shown below. Select the appropriate diagram for the application. Diagrams are popular examples
only. If your application is not shown, contact Amtrol Technical Support at 401.535.1216.
Boiler Controls
Typical Gas Valves (Non-Priority)
Typical Oil Burner (Non-Priority)
AQUASTAT
HONEYWELL
R4222D 1013
OR EQUIVALENT
DPDT RELAY
L1
1
HONEYWELL
R4222D 1013
OR EQUIVALENT
DPDT RELAY
W
Z
3
ZR
1
AQUASTAT
24V Thermostat Input (Priority)
T
B
1
AQUASTAT
3
2
HONEYWELL
R4222D 1013
OR EQUIVALENT
DPDT RELAY
2
2
4
L1
6
5
4
COIL
C1
6
HYDROMAX™
CIRCULATOR
T
3
4
6
5
5
HYDROMAX™
CIRCULATOR
COIL
L1
HYDROMAX™
CIRCULATOR
COIL
L1
L2
WHEN NO “ZR” TERMINAL IS AVAILABLE
GO TO THE SUPPLY SIDE OF THE HI LIMIT
L2
Zone Valves
Universal Sensor Kit
4-Wire
3-Wire
AQUASTAT
AQUASTAT
24VAC
24VAC
END
SWITCH
MOTOR
ZONE VALVE
TRANSFORMER
TRANSFORMER
ZONE VALVE
L2
L2
L1
END
SWITCH
L1
Installing Universal 10K Ohm Sensor Kit
HYDROMAX models with a mechanical aquastat
include a universal temperature sensor kit allowing
HYDROMAX to be used with any boiler control featuring
a standard “10K” DHW thermisor input (10,000 Ohms at
77° F). When installed, domestic water temperature is
regulated by the boiler and the HYDROMAX aquastat is
not used.
1. Unscrew and remove copper sensor bulb from
sensor well.
2. Insert Universal Sensor to bottom of sensor well.
3. Plug Universal Sensor into Extension cable.
4. Connect wire leads to DHW input terminals on
boiler control.
AQUASTAT
Other Applications
Multi-Zone Control
AQUASTAT
SENSOR BULB
(REMOVE)
Boiler Control Input
AQUASTAT
EXTENSION
CABLE
PLUG
DHW
L2
BOILER CONTROL
L1
DHW ZONE
DHW ZONE
X
X
UNIVERSAL SENSOR
IN SENSOR WELL
TO BOILER
HYDROMAX™
CIRCULATOR
OR ZONE VALVE
HYDROMAX™
CIRCULATOR
OR ZONE VALVE
-8-
BOILER
HYDROMAX
8. Startup Procedure
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.
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. Air pockets may appear at any hot water fixture. This is
considered normal and will clear as hot water is used.
3. START HEATER: Turn power on to the unit. Digital Control models
come pre-set to 120°F for safety. Mechanical controls should have
the knob rotated to the 120°F mark. The circulator or zone valve
should operate and the boiler should start.
4. CHECK OPERATION: The water heater will begin to heat.
Depending upon the size of the water heater, output of the boiler
and the space heating load, the unit should typically reach set
temperature within 15 to 60 minutes. If heating does not occur,
consult the troubleshooting section in this manual. Note: Large
heaters coupled with small boilers may exceed this time period
upon initial startup.
1. Close
Return
2. Fill
Boiler
3.
Purge
Air
5. SET TEMPERATURE: The control should be set to the minimum
temperature consistent with the user’s needs. This maximizes
efficiency and reduces scald potential.
6. The water heater and system should be periodically checked by a
licensed professional at least annually and more often as system ages.
9. Troubleshooting
PROBLEM
No hot water
Insufficient hot water
POSSIBLE CAUSES
SOLUTION
1. No power to unit
2. Circulator air-bound
3. Faulty circulator or zone valve
4. Faulty control
5. Boiler inoperable
1. Demand exceeds capacity
2. Temperature too low
3. Boiler lacks output for simultaneous heat & hot water
4. Fouled heat exchanger
2. Temperature set too high
3. Temperature sensor not fully inserted
4. Stuck zone valve
5. Flow check valve stuck open
1. Thermal expansion tank undersized or missing
2. Thermal expansion tank set improperly
3. City pressure too high
4. System over temperature
5. Faulty relief valve
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. Switching circuits should close. If not, replace control.
5. 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. Set up 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. 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 setting.
3. Re-insert temperature sensor.
4. Repair or replace.
5. Clean, repair or replace.
1. Install the properly sized 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.
1. Poor water quality
2. Sediment or suspended particles
1. Have water tested for contaminants.
2. Install sediment filter, purge unit more often to avoid future problems.
5. Insufficient heat exchanger flow
1. Improper plumbing
Water too hot
Relief valve dripping
or opening
Discolored water
at faucet
1. Improper or loose wiring
2. Boiler high limit has been reached
Boiler will not operate
3. Post Purge (POS) set too high
when calling for
4. Problem with boiler system
hot water
1. Check connections against wiring diagrams in this manual.
2. Boiler will periodically cycle on and off during operation.
3. 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.
-9-
10. 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
advised that 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.
Failure to use the correct replacement parts may
make your product unsafe.
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 water heater­has 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.
If a steel hydropneumatic tank is in place, replace it
with a properly sized diaphragm expansion tank.
Otherwise, significant heat transfer problems can occur by causing air to be
trapped in the heat exchanger. If the boiler system has a diaphragm
expansion tank and the boiler temperatures are being changed, resize the
expansion tank.
If installing on city water supply, a properly sized
thermal expansion tank is required with the water
heater and should be installed as set fo­
rth in the 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 water heater 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.
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.
Note: Inspect for shipping damage and notify freight carrier or store where
purchased immediately if damage is 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 obtained at the place of purchase.
Use proper safety equipment when installing.
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 to the
area adjacent to the appliance or to lower floors of the structure.
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.
If not installed by the boiler manufacturer, install a
low water cut-off or pressure 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.
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. 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.
CALIFORNIA PROPOSITION 65 WARNING! This
product contains a chemical known by the State of
California to cause cancer and to cause 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.htm
As in all plumbing products and water storage
vessels, bacteria can grow in this Product, especially
during times of non-use. Consult your local plumbing professional
regarding any steps you may wish to take to safely disinfect your home’s
plumbing system.
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. At least once every 3 years or if
discharge is present, a licensed contractor should inspect the temperature
and pressure relief valve and replace if corrosion is evident or the valve
does not function. FAILURE TO INSPECT THIS VALVE AS DIRECTED
COULD RESULT IN UNSAFE TEMPERATURE OR PRESSURE
BUILD-UP WHICH CAN RESULT IN PRODUCT FAILURE, SERIOUS
INJURY OR DEATH AND/OR SEVERE PROPERTY DAMAGE AND
VOID THE PRODUCT WARRANTY.
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 water heater
pressure must be limited to 150 psig maximum by the installation of a
temperature and pressure relief valve (included). The relief tube must be
plumbed to a suitable drain per code. No reducing coupling or other
restriction may be placed in this line.
-10-
11. REPLACEMENT PARTS
Description
ID
HM-41 Models
Heat Exchanger Replacement Kit
1
2713R002
HM-80 Models
2712R002
Top Cover Half (2 Required)
2
2704R512
2704R512
Mounting Panel, Digital Control
3
2704R525
2704R525
Mounting Panel, Mechanical Control
4
2704R498
2704R498
Ener-G-NET™ Digital Temperature Control
5
940R2
940R2
Temperature Sensor (Thermistor)
-
2704-259
2704-259
Water Sensor
-
2704-495
2704-495
Mechanical Temperature Control
6
2704-093
2704-093
Universal 10K Sensor Kit
-
2704-529
2704-529
Turbulator™ Cold Water Inlet Tube
7
2783R0003
2782R0001
T&P Safety Relief Valve
8
2700R116
2700R116
T&P Blowdown Tube
9
2783R004
2782R002
Bottom Drain Assembly
10
9340R160
9340R160
8
2
7
1
5
6
3
4
9
10
-11-
1400 Division Road, West Warwick, RI 02893
T: 401.884.6300
F: 401.885.2567
www.amtrol.com
HYDROMAX, Ener-G-NET, AMTROL, AMTROL logo, Therm-X-Trol, and EXTROL are registered trademarks of
AMTROL Inc. and affiliates in the U.S. and elsewhere. All rights reserved.
9040-694 (10/11)
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