Amtrol WHS, DC User Manual

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PREMIER SERIES

INDIRECT-FIRED WATER HEATERS

INSTALLATION & OPERATION INSTRUCTIONS

WHS-Series (Mechanical Control)

DC-Series (Mechanical Control)

PLEASE READ THE FOLLOWING INSTRUCTIONS CAREFULLY

INSTALLER: LEAVE THIS MANUAL WITH THE OWNER.

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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.

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.

READ CAREFULLY THE PRODUCT

INSTALLATION & OPERATION INSTRUCTIONS. 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.

PERSONAL INJURY MAY OCCUR IF THE COVER BECOMES DETACHED.

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.

DO NOT LIFT OR CARRY WATER HEATER BY THE TOP COVER. WATER HEATER DAMAGE OR

The heat transfer medium must be water or other nontoxic fluid having a toxicity rating or class of

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PLEASE READ THE FOLLOWING INSTRUCTIONS CAREFULLY

IMPORTANT GENERAL SAFETY INFORMATION -

ADDITIONAL SPECIFIC SAFETY ALERTS APPEAR IN THE FOLLOWING INSTRUCTIONS.

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.

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 DOUBLE-

WALLED HEAT EXCHANGER MODELS. Glycol is a poisonous 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.

Do not connect the water heater domestic

supply with baseboard or other space 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).

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 heating can

be lost in the home in this 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 can be 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 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.

1. Non-Priority System - The controls of the water heater must be wired as a separate heating zone with a standard zone valve or a separate circulator dedicated to the water heater “zone”.

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.

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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.

Required Components and Accessories Checklist

MODEL CIRCULATOR ZONE VALVE

SHUTOFF

VALVE

WHS Models See Chart Full Port 4 1

DC Models See Chart Full Port 6 1

All installations require an adequate amount of sealing tape or pipe dope for threaded joints. See heat exchanger pressure drop chart to determine pump head requirements.

Heat Exchanger Pressure Drop

Double Wall Heat Exchanger

Pressure Drop (FT)

VACUUM

BREAKER

RELIEF

VALVE

150 psig/210°F

Included

150 psig/210°F

Included

THERMAL EXPANSION

60 Gal. Models: 4.4 Gal. 80 Gal. Models: 4.4 Gal.

120 Gal. Models: 4.4 Gal.+

80 Gal. Models: 4.4 Gal.

120 Gal. Models: 4.4 Gal.+

Single Wall Heat Exchanger

TANK

DRAIN

Included

0 2

4 6 8 10 12

Flow (GPM)

If a steel hydropneumatic tank is in place,

expansion tank. Otherwise, significant heat transfer problems can occur by causing air to be trapped in the heat exchanger. If the

replace it with a properly sized diaphragm

boiler system has an existing expansion tank and the boiler temperatures are being changed, resize the existing diaphragm expansion tank.

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Plumbing

Domestic Water Piping

1. Connect the cold water supply to the connection 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 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 temperature control is adjusted to 120°F, when shipped from the factory.

4. Install the T & P relief valve and plumb a blow down tube. Plumb to within 6 inches above a floor drain or as directed by plumbing code.

Do not drill, puncture or otherwise penetrate

hangers or other hardware into the exterior of the tank.

Clearance From Combustible Surfaces

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

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

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

the outer tank shell. Do not screw pipe

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

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

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

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 plumbed to

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 or use a circulator pump with integral check valve. 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.

EXPLOSION HAZARD. Do not install to a

15 psig). An explosion could occur.

Recommended Clearance for Servicing

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

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

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

the suction side of any heating circulators.

high pressure steam boiler (greater than

HEAD ROOM .......36"

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

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WHS Models

PIPING USING SEPARATE CIRCULATOR PUMP (RECOMMENDED)

PIPING USING ZONE VALVE WITH EXISTING HEATING SYSTEM CIRCULATOR

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Mechanical Aquastat Wiring Diagrams

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.

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

Zone Valves

CIRCULATOR

END

SWITCH

ZONE VALVE

Typical Gas Valves (Non-Priority)

AQUASTAT

L1L2

HONEYWELL

R4222D 1013

OR EQUIVALENT

DPDT RELAY

4 6

COIL

TRANSFORMER

AQUASTAT

3-Wire

24VAC

TRANSFORMER

CIRCULATOR

L1L2

4-Wire

24VAC

24V Thermostat Input (Priority)

HONEYWELL R4222D 1013

OR EQUIVALENT

DPDT RELAY

4 6

COIL

AQUASTAT

ZONE VALVE

MOTOR

END

SWITCH

CIRCULATOR

Other Applications

Multi-Zone Control

L1L2

DHW ZONE

TO BOILER

AQUASTAT

CIRCULATOR

OR ZONE VALVE

Boiler Control Input

AQUASTAT

DHW ZONE

CIRCULATOR

OR ZONE VALVE

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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. 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.

5. SET TEMPERATURE: The control should be set to the

6. MAINTENANCE: The water heater and system should be

Troubleshooting

PROBLEM POSSIBLE CAUSES SOLUTION

1. No power to unit

2. Circulator air-bound

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

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 bulb 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. Problem with boiler system

Warranty

WHS Series and DC Series: 10 Year Limited Warranty Residential

5 Year Limited Warranty Commercial

Visit www.amtrol.com for complete warranty details.

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 circuit 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 bulb.

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. Have boiler diagnosed for proper operation.

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.

minimum temperature consistent with the user’s needs. This maximizes efficiency and reduces scald potential.

Painful scalding with possible serious and permanent injury can occur if the

temperature is set too high or the thermostat is not functioning properly.

periodically checked by a licensed professional at least annually and more often as system ages.

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1400 Division Road, West Warwick, RI 02893 USA

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www.amtrol.com