Amtrol AX-240V, AX-15V, AX-260V, AX-40V, AX-60V User Manual

INSTALLATION, OPERATION & SERVICE INSTRUCTIONS

EXTROL® AX SERIES

1400 Division Road, West Warwick, RI 02893 T: 401.884.6300 F: 401.885.2567 www.amtrol.com

Pressurized Expansion Tanks (ASME)

For Horizontal and Vertical Models

For Models:

AX-15(V)

AX-20(V)

AX-40(V)

AX-60(V)

AX-80(V)

AX-100(V)

AX-120(V)

AX-144(V)

AX-180(V)

AX-200(V)

AX-240(V)

AX-260(V)

AX-280(V)

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.

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 240° F. Do not adjust the pre-charge or re-pressure this Product except for any adjustments required at the time of initial
installation, especially if Product corroded, damaged or with diminished integrity. Adjustments to pre-charge must be done at ambient temperature only.
Failure to properly size the Product or follow these instructions may result in excessive strain on the system lead to Product failure, serious or fatal personal
injury, leakage and/or property damage.

THIS IS A 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 #: 9017-093 (04/11)

PLEASE READ THE FOLLOWING INSTRUCTIONS CAREFULLY

EXPLOSION HAZARD. FAILURE TO FOLLOW INSTRUCTIONS IN THE ACCOMPANYING PRODUCT MANUAL CAN CAUSE RUPTURE
OR EXPLOSION, POSSIBLY CAUSING SERIOUS OR FATAL INJURY, LEAKING OR FLOODING AND/OR PROPERTY DAMAGE.

Potable Water and Radiant Heating Warning.

This Product must not be used in radiant
heating, potable water or open systems of any kind. These systems
contain oxygenated water which will cause internal corrosion and
premature Product failure. Use a Therm-X-Trol

®

for potable water
systems and a Radiant Extrol™ for radiant heating systems. Mount
vertically only. Do not install on dead-end pipe.

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

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 viewed at www.amtrol.com. Use proper safety equipment
when installing.

FAILURE TO PROPERLY SEAL WILL RESULT
IN LOSS OF PRECHARGE CAUSING

PRODUCT TO FAIL.

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.

Location of EXTROL® Expansion Tanks

DO NOT LOCATE THIS PRODUCT WHERE

TO THE SURROUNDING PROPERTY.

The AMTROL
the mechanical room (or building). If multiple tanks are installed, they should all
be on the same level.

®

expansion tank may be placed in any convenient position within

LEAKING OR FLOODING COULD CAUSE DAMAGE

Point of Connection

Unlike a conventional tank, the EXTROL® sealed air cushion does not require
replenishment so DO NOT connect to an air separator or other air collection
device.
As with any expansion tank, it is recommended that the EXTROL
to the suction side of the pump. This will prevent the pump head from becoming
subtractive which may result in entry of air and vapor formation at high points in
the system.
By connecting the EXTROL
water into tank is ensured reducing energy waste.
Low pressure drop components such as air separators and boilers may be placed
between point of connection and pump suction if desired. System design will
dictate the feasibility of this.
Natural convection losses and the entry of air into tanks are eliminated by
connection to the side or underside of main pipe. The piping should be pitched up
and away from the EXTROL

®

on the boiler return, displacement of coolest system

®

to eliminate any potential air traps.

®

be connected

Installation

5. After making sure the air charge is correct, replace the 1 1/2” plug over the
air valve.

6. The EXTROL
EXTROL

7. Using the table below, select appropriate pipe size. Connection to each
EXTROL
removal if required. Make up and fill valves, whether manual or automatic,
should be tied into the connecting line. This will ensure that pump operation
will not affect valve operation.

®

may now be piped to the system (use the suggested

®

piping diagrams on the next page).

®

must have a lock shield gate valve and union to allow isolation and

Operational Limits

Maximum Operating Pressure: As stamped on nameplate
Maximum Operating Temperature: 240 °F
Minimum Operating Temperature: 35°F (non-glycol application)
If unit is being installed in a glycol system where minimum temperatures
fall below 35°F, contact the AMTROL technical service department at (401)
535-1216.

Operating Instructions

1. Check the expansion tank pre-charge before the system is filled with water.

The charge is 12 psig unless noted otherwise on the tank label. Check to
make sure this is the correct pre-charge pressure specified for the system.

2. If the tank pre-charge pressure needs to be changed on a dry system follow

the following procedure:

a. Check the expansion tank air pressures at the pre-charge connection with

an accurate tire type pressure gauge. The pre-charge connection is the same
kind of connection found on automobile tires.

b. If the pressure is low, charge the tank with nitrogen gas or with oil free

compressed air. Check the pressure frequently during this process as you
would when filling a tire with air.

Danger: Excessive pressure can cause tank to explode. Exercise
care when filling a tank with air so the pressure does not exceed

that required or does not exceed the working pressure of the
tank as stamped on the nameplate. Failure to follow these instructions will
result in serious personal injury or death and property damage.

3. If, after the system has been filled with water and operating, it is found that

the expansion tank pre-charge must be changed use the following procedure:

a. Turn off the heat source and allow the system water to cool to ambient

temperature.

b. Close the lock-shield valve in the tank-to-system piping.

IMPORTANT: Expansion tank cannot be properly air charged

other than at ambient temperature.

c. Open the drain valve to empty the water from the tank.
d. Check the tank air pressure at the pre-charge connection with an accurate

tire type air gauge.
e. Refer to 2b above.
f. Close the drain valve, open the lock-shield valve and turn on the heat

source.
g. Relock the lock-shield valve.

THIS PRODUCT MUST BE INSTALLED BY A
QUALIFIED PROFESSIONAL.

1. Note location of system connection, air charge valve and drain connection on
tank.

2. Remove the plug or pipe cap from the system connection.

3. Remove the 1 1/2” NPT plug covering the air charge valve.

4. Before making any connection to the tank, check the tank and air charge (use
an accurate pressure gauge). The air pressure must be equal to the minimum
system pressure at the tank location.

Firing Rate Length of Pipe Connecting
of Boiler Tank to System:
MBTU/H Below 11’ 11’ – 30’ 31’ – 100’

2,000 1/2” 3/4” 1”
4,000 3/4” 1” 1 1/4”
8,000 1” 1 1/4” 1 1/2”
12,000 1 1/4” 1 1/2” 2”
16,000 1 1/4” 2” 2 1/2”
20,000 1 1/2” 2” 2 1/2”