Amtrol HM-41Z, HM-41L, HM-80L, HM-80Z User Manual

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Page 1

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

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.

medium must be limited to 30 PSIG by an approved safety or relief valve.

9040-694 (10/11)

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

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

Page 2

1. Table Of Contents

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

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

4. HYDROMAX™ Plumbing ...............................................

5. Ener-G-NET™ Wiring ..................................................

6. Ener-G-NET™ Setup & Adjustment ...............................

5-6

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

MODELS. 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.

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.

❑ 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).

1. Non-Priority System - The controls of the water heater

Glycol is a poisonous substance. To avoid

must be wired as a separate heating zone with a standard zone valve or a separate circulator dedicated to the water heater “zone”.

DOUBLE-

Do not connect the water heater supply with baseboard or other space

WALLED HEAT EXCHANGER

domestic

7. Mechanical Aquastat Wiring ..........................................

8. Startup Procedure .........................................................

9. Troubleshooting .............................................................

10. General Safety Information .........................................

11. Replacement Parts ...................................................... 11

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

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

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.

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.

❑ 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.

heating can be lost in the home in this

can be

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Page 3

3. Required Components And Accessories Checklist

THERMAL

EXPANSION

TANK

MODEL

CIRCULATOR

PERFORMANCE

ZONE VALVE

SHUTOFF

VALVES

RELIEF VALVE

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 2 Piece Cover Removal and Installation

Boiler Return

Boiler Supply

Cold Water

Inlet

Retaining Screws (2)

Heat Exchanger Pressure Loss

Head Loss (Feet)

0 2 4 6 8

Flow (Gallons Per Minute)

Hot Water

Outlet

Heat Trap

Removing Front Half: Depress both tab buttons to detach one side at a time.

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.

Removing Entire Cover: Remove front half, loosen both retaining screws and remove rear half.

Tab Buttons (4)

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Page 4

4. HYDROMAX™ Plumbing

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. 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.

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.

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

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.

than 15 psig). An explosion could occur.

plumbed to the suction side of any

EXPLOSION HAZARD. Do not install to

a high pressure steam boiler (greater

Clearance From Combustible Surfaces

LEFT SIDE ........... 1"

RIGHT SIDE.......... 1"

TOP ................9"

BLOWDOWN

REAR ...............1"

FLOOR .............. 0"

FRONT .............. 1"

WIRING AND AQUASTAT

TUBE

COLD WATER

SUPPLY

ON FRONT CAP HALF

BOILER SUPPLY

HOT WATER

OUTLET

BOILER RETURN

TEMPERATURE SENSOR WELL

TOP VIEW

FROM FRONT

Recommended Clearance for Servicing

LEFT............... 12"

RIGHT ............. 12"

HEAD ROOM .......36"

REAR ..............1"

FRONT ............. 30"

PIPING USING ZONE VALVE

REAR VIEW

(FOR CLARITY)

DRAIN

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Page 5

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.

Normally Open Close on call for hot water

Front Panel

Control

Screws (4)

Wiring Cover

Conduit Holes (3)

Ground Screw

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.

Post-Purge function

Normally Open Close on call for hot water

Normally Closed Open on call for hot water Priority function

{

Constant 24VAC or 120VAC

{

ORANGE

BLUE

VIOLET

WHITE

Power In

BLACK

Temperature

Sensor Plug

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.

Water

Sensor Plug

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Water

Sensor

Page 6

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

ZR Input Terminal

POWER BURNER PUMP PRIORITY

ORANGE

WHITE

BLACK

ORANGE

L1 ZR

BLUE

BOILERMATE

CIRCULATOR

Gas Valve Controls

24 Volt

POWER BURNER PUMP PRIORITY

VIOLET

CIRCULATOR

VIOLET

HEATING

High Limit (B Terminal)

POWER BURNER PUMP PRIORITY

ORANGE

WHITE

BLACK

ORANGE

L1 B

BLUE

BOILERMATE

CIRCULATOR

VIOLET

Millivolt

POWER BURNER PUMP PRIORITY

VIOLET

HEATING

CIRCULATOR

Triple-Aquastat

POWER BURNER PUMP PRIORITY

ORANGE

WHITE

BLACK

L1 BR

ORANGE

BLUE

BOILERMATE

CIRCULATOR

VIOLET

Self-Generating

POWER BURNER PUMP PRIORITY

VIOLET

HEATING

CIRCULATOR

WHITE

BLACK

ORANGE

L1 B

BLUE

BOILERMATE

CIRCULATOR

ORANGE

Other Applications

Multi-Zone Control: Using Post Purge

POWER BURNER PUMP PRIORITY

ORANGE

WHITE

TO BOILER

L1L2

BLACK

DHW ZONE

ORANGE

BLUE

VIOLET

BOILERMATE

CIRCULATOR

VIOLET

CIRCULATOR

VIOLET

HEATING

ORANGE

WHITE

BLACK

L1 BB2

ORANGE

Z W

BLUE

BOILERMATE

CIRCULATOR

Multi-Zone Control: No Post Purge

POWER BURNER PUMP PRIORITY

ORANGE

WHITE

24 OR 120VAC

TO BOILER

BLACK

L1L2

ORANGE

DHW ZONE

BLUE

BOILERMATE

CIRCULATOR

OR ZONE VALVE

-6-

VIOLET

HEATING

CIRCULATOR

VIOLET

ORANGE

BLACK

ORANGE

WHITE

L1 BB2

BLUE

BOILERMATE

CIRCULATOR

4-Wire Zone Valve

POWER BURNER PUMP PRIORITY

ORANGE

WHITE

24VAC

TRANSFORMER

BLACK

L1L2

ORANGE

BLUE

ZONE VALVE

BLUE

MOTOR

END

SWITCH

VIOLET

HEATING

CIRCULATOR

VIOLET

Page 7

6. Ener-G-NET™ Control Setup & Adjustment

Mode

Indicators

User

Modes

LED

Display

Installer Settings

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

Efficiency

Vacation

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

Differential Domestic hot water temperature drop before call for heat. Default is 10°F. 5,10*

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. 0-199MBH/Hr

*Available in Standard Mode only. **Available only when Differential setting is 10.

Traditional operation within preset temperature differential using a low and high limit.

On-Demand sensing reduces fuel consumption by limiting boiler operation during idle periods.

Reduced temperature setting minimizes boiler operation during anticipaated periods of non-use.

Domestic hot water setpoint. Default is 120°F

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.

90-150

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***

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.

***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

Idle

Heating

Displayed briefly during intial powerup to test LED display segments.

Static numeric [setpoint] readout (factory default shown) indicates domestic hot water setpoint.

Alternating On and [Setpoint] is displayed during a heating cycle while the circulator pump contacts are closed.

Sensor unplugged Sensor damaged

Error in boiler plumbing Zone valve stuck open Leak in sensor well

Faulty equipment Fouled heat exchanger No fuel

Standing water

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Page 8

7. Mechanical Aquastat Wiring Diagrams

Boiler Controls

Typical Oil Burner (Non-Priority)

HONEYWELL R4222D 1013

OR EQUIVALENT

AQUASTAT

DPDT RELAY

4 6

COIL

WHEN NO “ZR” TERMINAL IS AVAILABLE

GO TO THE SUPPLY SIDE OF THE HI LIMIT

HYDROMAX™

CIRCULATOR

Typical Gas Valves (Non-Priority)

HONEYWELL

R4222D 1013

OR EQUIVALENT

DPDT RELAY

4 6

COIL

AQUASTAT

HYDROMAX™

CIRCULATOR

24V Thermostat Input (Priority)

HONEYWELL R4222D 1013

AQUASTAT

OR EQUIVALENT

DPDT RELAY

4 6

COIL

Zone Valves Universal Sensor Kit

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

END

SWITCH

ZONE VALVE

3-Wire

AQUASTAT

24VAC

TRANSFORMER

L1L2

4-Wire

AQUASTAT

24VAC

MOTOR

ZONE VALVE

L1L2

END

SWITCH

HYDROMAX™

CIRCULATOR

Other Applications

Multi-Zone Control

L1L2

DHW ZONE

TO BOILER

AQUASTAT

HYDROMAX™

CIRCULATOR

OR ZONE VALVE

Boiler Control Input

AQUASTAT

DHW ZONE

HYDROMAX™

CIRCULATOR

OR ZONE VALVE

-8-

SENSOR BULB

(REMOVE)

DHW

BOILER CONTROL

EXTENSION

CABLE

PLUG

UNIVERSAL SENSOR

IN SENSOR WELL

HYDROMAXBOILER

Page 9

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.

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.

2. Fill

Boiler

1. Close Return

Purge

Air

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 POSSIBLE CAUSES SOLUTION

No hot water

Insufficient hot water

Water too hot

Relief valve dripping or opening

Discolored water at faucet

Boiler will not operate when calling for hot water

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

5. Insufficient heat exchanger flow

1. Improper plumbing

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. Poor water quality

2. Sediment or suspended particles

1. Improper or loose wiring

2. Boiler high limit has been reached

3. Post Purge (POS) set too high

4. Problem with boiler system

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. Have water tested for contaminants.

2. Install sediment filter, purge unit more often to avoid future problems.

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-

Page 10

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 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.

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.

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.

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.

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11. REPLACEMENT PARTS

Description ID HM-41 Models HM-80 Models

Heat Exchanger Replacement Kit 1 2713R002 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

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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afliatesintheU.S.andelsewhere.Allrightsreserved.

9040-694 (10/11)