Amtrol BoilerMate RTR, WH-7, BoilerMate Top Down, WH-9 User Manual

INSTALLATION, OPERATION

West Warwick, Rhode Island 02893

& MAINTENANCE

INSTRUCTIONS

BOILERMATE

INDIRECT-FIRED WATER HEATERS

MODELS COVERED:

• WH-7 & 9 Classic Series

• Top Down

• RTR models

• WHS Premier Series

™

TD 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

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.

Part #: 9040-586 (07/08)

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

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.

1. TABLE OF CONTENTS

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

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

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

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

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

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

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

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

2. PRE-INSTALLATION CHECKLIST

IMPORTANT STEPS AND DECISIONS REQUIRED BEFORE INSTALLATION

M THIS PRODUCT MUST BE INSTALLED AND

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.

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

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.

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.

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

System:

Two options are available when wiring the controls of the BOILERMATE distribution elements).

1. Non-Priority System - The controls of the BOILERMATE zone with a standard zone valve or a separate circulator dedicated to the BOILERMATE

NOTICE: In this non-priority option, the BOILERMATE will be supplied just as another zone. This means that if all space heating zones call for hot boiler water at the same

or the rest of your plumbing system.

USE GLYCOL ONLY WITH DOUBLE-WALLED HEAT EXCHANGER

Do not connect the BOILERMATE® domestic supply with baseboard

in the space heating system (boiler and

must be wired as a separate heating

“zone”.

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

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

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

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

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

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

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

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.

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.

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.

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 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.

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 BOILEMATE®.

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3. REQUIRED COMPONENTS AND ACCESSORIES CHECKLIST

SHUTOFF VACUUM RELIEF THERMAL EXPANSION

MODEL CIRCULATOR ZONE VALVE* VALVE BREAKER VALVE TANK DRAIN

Residential = 5GPM *If Circulator not used Required

WH SERIES Commercial = 10GPM 3/4” Full Port 4 1 Included (See Therm-X-Trol® Included Except “P” Models or 1” STD Sizing Guide)

5GPM *If Circulator not used Required TD SERIES Except “P” Models 3/4” Full Port 4 1 Included (See Therm-X-Trol® Included or 1” STD Sizing Guide)

Required RTR SERIES Included N/A 4 1 Included (See Therm-X-Trol® Included Sizing Guide)

Residential = 5GPM *If Circulator not used Required WHS SERIES Commercial = 10GPM 3/4” Full Port 4 1 Included (See Therm-X-Trol® Included Except “P” Models or 1” STD 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®.

If a steel hydropneumatic tank is in place, AMTROL® recommends replacing it with a

properly sized EXTROL heat transfer problems can occur by causing air to be trapped in the heat exchanger. If the boiler system has an EXTROL EXTROL

or Radiant EXTROL® expansion tank and the boiler temperatures are being changed, resize the

or Radiant EXTROL® expansion tank.

or Radiant EXTROL® expansion tank. Otherwise, significant

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4. WH-7 & 9 CLASSIC SERIES PIPING INSTALLATION

DOMESTIC WATER PIPING

1. Thread the included 3/4” brass tee onto the pipe marked COLD WATER.

2. Screw the

tee.

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

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.

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

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.

/4” drain valve into the opposite end of the brass

or equivalent) is

BOILER PIPING

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

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.

required with the BoilerMate forth in the THERM-X-TROL

Clearance From Combustible Surfaces

LEFT SIDE ............1”

RIGHT SIDE ...........1”

TOP .................9”

Recommended Clearance For Servicing

LEFT .................12”

RIGHT................12”

FRONT ...............30”

plumbed to the suction side of

If installing on city water supply a properly sized THERM-X-TROL

and should be installed as set

product installation manual.

REAR ................1”

FLOOR ...............0”

FRONT ...............1”

HEAD ROOM ..........9”

REAR ................1”

HOT WATER OUTLET

BOILER RETURN (Top Left)

BOILER SUPPLY (Top Right)

COLD WATER INLET (Bottom Center)

T&P RELIEF VALVE

UNION NUT

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PIPING USING SEPARATE CIRCULATOR PUMP (RECOMMENDED)

PIPING USING ZONE VALVE WITH EXISTING HEATING SYSTEM CIRCULATOR

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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.

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

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

4. After completing the boiler piping, slowly open the boiler fill valve and pressurize the BoilerMate

temperature.

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 required with the BoilerMate forth in the THERM-X-TROL

and should be installed as set

product installation manual.

Clearance From Combustible Surfaces

LEFT SIDE ............1”

RIGHT SIDE ...........1”

TOP .................9”

COLD WATER INLET (Top Center)

BOILER SUPPLY (Bottom Right)

BOILER RETURN (Bottom Left)

REAR ................1”

FLOOR ...............0”

FRONT ...............1”

Recommended Clearance For Servicing

LEFT .................12”

RIGHT................12”

HEAD ROOM ..........9”

REAR ................1”

FRONT ...............30”

T&P RELIEF VALVE OUTLET

HOT WATER OUTLET

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DRAIN VALVE

PIPING USING SEPARATE CIRCULATOR PUMP (RECOMMENDED)

PIPING USING ZONE VALVE WITH EXISTING HEATING SYSTEM CIRCULATOR

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6. READY-TO-RUN RTR-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.

Note: If installing on a city supply, ensure a dedicated Thermal Expansion tank (Therm-X-Trol 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.

COLD WATER INLET

T&P RELIEF VALVE

HOT WATER OUTLET

OUTLET

or equivalent) is

BOILER PIPING

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

2. Pipe the BOILER RETURN connection to the boiler return

line.

Be sure the return line is NOT

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.

required with the BoilerMate forth in the THERM-X-TROL

Clearance From Combustible Surfaces

LEFT SIDE ............1”

RIGHT SIDE ...........1”

TOP .................9”

Recommended Clearance For Servicing

LEFT .................12”

RIGHT................12”

FRONT ...............30”

CIRCULATOR

plumbed to the suction side of any

If installing on city water supply a properly sized THERM-X-TROL

and should be installed as set

product installation manual.

REAR ................1”

FLOOR ...............0”

FRONT ...............1”

HEAD ROOM ..........36”

REAR ................1”

BOILER SUPPLY

BOILER RETURN

DRAIN VALVE

TOP VIEW

SIDE VIEW

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

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7. WHS PREMIER SERIES PIPING INSTALLATION

DOMESTIC WATER PIPING

1. Thread the included brass tee onto the pipe marked COLD WATER.

2. Screw the drain valve into the opposite end of the brass

tee

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

4. Thread the included T&P Safety Relief Valve into the offset

/4” port on the top plate. Install a blowdown tube to within

6 inches of a floor drain or as directed by plumbing code.

5. Connect the center hot water outlet port on the top plate to the domestic hot water system.

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

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

BOILER PIPING

2. Pipe the BOILER RETURN connection to the boiler return

line.

Be sure the return line is NOT

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

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

required with the BoilerMate forth in the THERM-X-TROL

plumbed to the suction side of any

temperature.

loop. Check for leaks

If installing on city water supply a properly sized THERM-X-TROL

and should be installed as set

product installation manual.

Clearance From Combustible Surfaces

LEFT SIDE ............1”

RIGHT SIDE ...........1”

TOP .................9”

BOILER SUPPLY (Top Right)

REAR ................1”

FLOOR ...............0”

FRONT ...............1”

HOT WATER OUTLET

BOILER RETURN (Top Left)

Recommended Clearance For Servicing

LEFT .................12”

RIGHT................12”

HEAD ROOM ..........36”

REAR ................1”

FRONT ...............30”

T&P RELIEF VALVE

COLD WATER INLET

(Bottom Center)

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+ 22 hidden pages

Amtrol BoilerMate RTR, WH-7, BoilerMate Top Down, WH-9 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual