Amtrol WHS, DC User Manual

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

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.

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

20

15

Double Wall Heat Exchanger

10

Pressure Drop (FT)

5

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

Included

0

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.