Amtrol TD-7ZDW, TD-7Z, TD-41ZDW, TD-41Z User Manual

INSTALLATION, OPERATION

West Warwick, Rhode Island 02893

& MAINTENANCE

INSTRUCTIONS

BOILER MATE

INDIRECT-FIRED WATER HEATERS WITH

TOP-MOUNTED COIL

TOP-DOWN

MODELS: TD-7Z

TD-41Z TD-7ZDW TD-41ZDW

The heat transfer medium should be water. If any product other than water is used, it must be a non-toxic fluid suitable for human ingestion as determined by the FDA

WARNING: REVIEW ALL GENERAL SAFETY INFORMATION ON PAGE 3 PRIOR TO INSTALLATION.

Your AMTROL BOILER MATE™ has been carefully assembled and factory tested. To enjoy the full service your BOILER

TE™ can pr

MA been completed, make sur AMTROL product. You should also read carefully the sections describing proper product maintenance, and follow the

ed procedures as you use your BOILER MATE™. Return this booklet to its original envelope, and keep it with the

equir

r BOILER MA

www.amtrol.com or ask your AMTROL supplier for any updates relating to your product.

Our goal is to ensure you are fully satisfied with your new BOILER MATE™. If any questions or concerns arise, call Technical Service at 401-535-1216.

Part #: 9040-628 REV

ovide, you should r

e you also follow the enclosed post-installation and start-up checklists befor

TE™.

THIS IS THE SAFETY ALERT SYMBOL. IT IS USED TO ALERT YOU TO POTENTIAL PERSONAL INJUR SYMBOL TO REDUCE THE RISK OF POSSIBLE INJUR

This manual may become out-of-date by later amendments. Check our web site,

Y AND OTHER HAZARDS. OBEY ALL SAFETY MESSAGES THA

B (7/04)

ead and follow all of the instructions in this manual. When all installation steps have

e using your

T FOLLOW THIS

Y AS WELL AS PROPER

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TY DAMAGE.

TABLE OF CONTENTS

1. GENERAL SAFETY INFORMATION......................................................................................3

2. PRE-INSTALLATION CHECKLIST

Important Steps and Decisions Required Before Installation

3. REQUIRED COMPONENTS AND ACCESSORIES CHECKLIST .......................................5

........................................................................................4

FORCED HOT WATER, CLOSED HYDRONIC HEATING SYSTEMS

4. INSTALLATION - Forced Hot Water, Closed Hydronic Heating System .........................6

A. General Installation Requirements ..................................................................................6

B. Piping .................................................................................................................................7

C. Electrical Wiring ................................................................................................................8

D. Post-Installation and Start-up Check List.......................................................................9

ALL SYSTEMS

6. OPERATION AND MAINTENANCE.....................................................................................11

7. REPLACEMENT PARTS.......................................................................................................12

8. TROUBLESHOOTING CHECKLIST ....................................................................................13

9. SERVICE RECORD...............................................................................................................14

10. AMTROL LIMITED PRODUCT WARRANTY......................................................................15

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1. GENERAL SAFETY INFORMATION

IMPOR

TANT GENERAL SAFETY INFORMATION - ADDITIONAL SPECIFIC SAFETY ALERTS

APPEAR IN THE FOLLOWING INSTRUCTIONS

EXPLOSION HAZARD: DO NOT INSTALL TO A HIGH PRESSURE STEAM BOILER (greater than 15 psig). AN EXPLOSION COULD OCCUR.

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

TEMPERATURE AND PRESSURE RELIEF VALVE (INCLUDED).

EXCESSIVE LEVELS THAT MAY CAUSE SERIOUS SCALDING, EVEN IF THE TEMPERATURE SETTING IS CORRECT. 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 AFTER INSTALLATION AND ANY SERVICING OF THE UNIT.

TANK PRESSURE MUST BE LIMITED TO 150 PSIG MAXIMUM BY THE INSTALLATION OF A

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 NOTES A SLOWER RESPONSE TIME OF INFANTS, AGED, DISABLED AND OTHER PERSONS INCREASES THE HAZARD TO THEM 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.

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

SCALDING HAZARD: A CHECK VALVE MUST BE INSTALLED IN THE BOILER RETURN LINE TO PREVENT GRAVITY FLOW THROUGH THE HEAT EXCHANGER. THIS CAN CAUSE OVER HEATING AND RESULT IN SERIOUS SCALDING.

IF NOT INSTALLED BY THE BOILER MANUFACTURER, INSTALL A LOW WATER CUT-OFF OR PRESSURE REDUCING VALVES MUST BE INSTALLED ON YOUR BOILER SO THAT LEAKING FROM

FIRE, AN EXPLOSION HAZARD EXISTS.

LICENSED PROFESSIONAL MUST INSTALL AND PERIODICALLY INSPECT AND SERVICE THE UNIT. A DRIP PAN, CONNECTED TO AN ADEQUATE DRAIN MUST BE INSTALLED IF LEAKING OR FLOODING CAN CAUSE PROPERTY DAMAGE.

YOUR HOME’S PLUMBING SYSTEM.

SATISFACTORY PERFORMANCE AND PREVENT PREMATURE FAILURE.

ANY PLUMBING FIXTURE WILL NOT RESULT IN A DRY BOILER; IF THE BOILER CONTINUES TO

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. ALSO, MAKE SURE A VACUUM BREAKER IS IN PLACE TO AVOID DAMAGING THE LINER.

VOID RISK OF INGESTING A TOXIC FLUID. THE HEAT TRANSFER MEDIUM SHOULD BE WATER.

YCOL MUST BE USED, IT SHOULD ONL

IF GL EXCHANGERS.

ANK, LIKE MOST T

THIS T MAY BURST AND/OR LEAK OR FLOOD (AND IN RARE CASES EXPLODE) WHICH CAN CAUSE SERIOUS OR FATAL PERSONAL INJURY AND PROPERTY DAMAGE. TO MINIMIZE RISK, A

AS IN ALL PLUMBING PRODUCTS AND W YOUR BOILER MATE PLUMBING OFFICIAL REGARDING ANY STEPS YOU MAY WISH TO TAKE TO SAFELY DISINFECT

TER QUALITY CAN SIGNIFICANTL

W TEST FOR CORROSIVE ELEMENTS, ACIDITY CONTAMINANTS, INCLUDING CHLORINE AND TREAT YOUR WATER APPROPRIATELY TO INSURE

ANKS UNDER PRESSURE, WILL OVER TIME CORRODE OR F

, ESPECIALLY DURING TIMES OF NON-USE. CONSULT YOUR LOCAL

Y INFLUENCE THE LIFE OF YOUR PRODUCT

Y BE USED WITH DOUBLE-W

TER STORAGE VESSELS, BACTERIA CAN GROW IN

AL SOLIDS, AND OTHER RELEV

, TOT

ALLED HEA

AIL AND/OR

, YOU SHOULD

ANT

FOLLOW ALL OF THE INSTRUCTIONS AND RECOMMENDATIONS CONTAINED IN THIS MANUAL, AND THE FOLLOWING ADDITIONAL SPECIFIC WARNINGS. FAILURE TO DO SO IS UNSAFE

PROPER

AILURE TO FOLLOW THE ABOVE W

F AND/OR PROPERTY DAMAGE, AND WILL VOID THE WARRANTY.

TY DAMAGE.

CAN CAUSE SERIOUS SCALDING, EXPLOSION, SERIOUS OR FATAL PERSONAL INJURY AND

ARNINGS MAY RESULT IN SERIOUS OR FATAL PERSONAL INJURY

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AND

2. PRE-INSTALLATION CHECKLIST

IMPORTANT STEPS AND DECISIONS REQUIRED BEFORE INSTALLATION

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.

THIS PRODUCT MUST BE INSTALLED AND

DRIP P property damage, install with a drip pan connected to an adequate working drain kept clear at all times.

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 af MATE™ or the rest of your plumbing system.

damage to surrounding property.

MODELS. Glycol is a hazardous substance. To avoid seepage or leakage of glycol to surfaces where children 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 children and animals should be protected from contact with the unit.

other space heating units or elements. Any contaminants in the baseboard units will contaminate the potable water in the BOILER MATE™ and also adversely affect its performance.

AN AND DRAIN: To avoid leaking and/or

fect the BOILER

Do not locate this product where leaking and flooding could cause

USE GLYCOL ONLY WITH DOUBLEWALLED HEAT EXCHANGER

Do not connect the BOILER MATE™ domestic supply with baseboard or

2. Priority System - Under this wiring option the

BOILER MATE™ will be supplied before space heating.

In limited cir

heating can be lost in the home in this priority mode. Any demand for space heating is postponed until the BOILER MATE™ has reached its set temperatur 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 BOILER MATE™ can be controlled with either a motorized zone valve or a circulator.

1. Zone valve (system flow of 4-8 gpm). If a zone valve is to

be used, a minimum flow rate of 4 gpm with all zones in use is required with a maximum of 8 gpm with only the BOILER MATE™ in use. Be sure the zone valve chosen has a maximum pressure drop (Cv = 4) when fully opened.

2. Separate circulator. The recommended way to provide

adequate flow through the BOILER MATE™ heat exchanger is to use a separate dedicated circulator with a minimum flow rate of 4 gpm (10 feet of head minimum) and maximum flow rate of 8 gpm. This option may be used even though the heating system utilizes zone valves.

e. This delay in supplying the space heating

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 r which is also required by most codes.

cumstances, space

e a low-water cut-of

equir

Wiring Options. Select either a Non-Priority or Priority

System:

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

1. Non-Priority System - The controls of the BOILER MATE™ must be wired as a separate heating zone with a standard zone valve or a separate circulator dedicated to the BOILER MA

NOTICE: In this non-priority option, the BOILER MATE™ 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 BOILER MA water to "r 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.

TE™ in the space heating system (boiler and

TE™ "zone".

TE™ may not be supplied with enough hot boiler

ecover" adequately

. The delivery of domestic hot

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Installation of a vacuum br

damage to the BOILER MATE™ when drained.

eaker is r

equired to prevent

3. REQUIRED COMPONENTS AND ACCESSORIES CHECKLIST

TD-7Z, TD-41Z, TD-7ZDW, TD-41ZDW

COMPONENTS CHECKLIST

The following is a checklist of components required for proper installation of these

A. Separate circulator

1 each - circulator (4-8 gpm)

•

• 1 each - positive shut-off weighted check valve

B. Use of heating system zone circulator

1 each - zone valve

•

C. Also Required:

• 4 each - unions

• 4 each - shut off valve

• 1 each - vacuum breaker

• 1 each - T & P relief valve (included)

• 1 each - A THERM-X-TROL®expansion tank - REQUIRED IF a Back flow preventer, check valve or pressure reducing valve is installed anywhere between the BOILER MATE™ and the city main.

• As needed - pipe dope or Teflon tape

• Do not forget an EXTROL side of your system.

BOILER MATE™ models, both Priority and Non-Priority:

and thermal expansion - an expansion tank is required on the boiler

If a steel hydropneumatic tank is in place, AMTROL recommends

replacing it with a properly sized EXTROL®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 EXTROL®expansion tank and the boiler temperatures are being changed, resize the EXTROL®expansion tank.

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+ 11 hidden pages

Amtrol TD-7ZDW, TD-7Z, TD-41ZDW, TD-41Z User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual