Amtrol EXTROL 400 LBC, EXTROL 200 LBC, EXTROL 300 LBC, EXTROL 600 LBC, EXTROL 130 LBC User Manual

INSTALLATION, OPERATION & SERVICE INSTRUCTIONS

EXTROL® LBC SERIES

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

LBC Series Bottom Connection Bladder Series

Pressurized Expansion Tanks (ASME)

FOR MODELS:

35 LBC

50 LBC

85 LBC

100 LBC

130 LBC

165 LBC

200 LBC

300 LBC

400 LBC

500 LBC

600 LBC

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 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 #9017-095 (04/11)

PLEASE READ THE FOLLOWING INSTRUCTIONS CAREFULLY

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.

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.

GENERAL SAFETY INFORMATION -

ADDITIONAL SPECIFIC SAFETY ALERTS
APPEAR IN THE FOLLOWING INSTRUCTIONS.

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
LEAKING OR FLOODING COULD CAUSE

DAMAGE TO THE SURROUNDING PROPERTY.

The AMTROL® expansion tank may be placed in any convenient position
within the mechanical room (or building). If multiple tanks are installed,
they should all be on the same level.

6. The EXTROL® may now be piped to the system (use the suggested
EXTROL® piping diagrams on the next page).

7. Using the table below, select appropriate pipe size. Connection to
each EXTROL® must have a lock shield gate valve and union to allow
isolation and 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.

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

[phone].

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.

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® be
connected 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® on the boiler return, displacement of coolest
system 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® to eliminate any potential air traps.

Installation

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.

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

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.

IMPORTANT: Expansion tank cannot be properly
air charged other than at ambient temperature.

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

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.

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”