West Warwick, Rhode Island 02893 INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS BOILERMATE® INDIRECT-FIRED WATER HEATERS MODELS COVERED: • WH Classic Series • Top Down™ TD Series • RTR models • WHS Premier Series MODELS CODES: P: L: Z: C: DW: RTR: Packaged with circulator & Smart Control™ Less Circulator, with Smart Control™ Dial Aquastat High-output commercial exchanger Double-wall heat exchanger Pre-piped and wired INSTALLER: LEAVE THIS MANUAL WITH THE OWNER IMPORTANT GENERAL SAFETY INFORMATI
1. TABLE OF CONTENTS 2. Pre-Installation Checklist..................................................2 10. Wiring All Ready-To-Run (RTR) Models........................ 23 3. Required Components and Accessories Checklist..........3 11. Startup Procedure For All Models................................. 25 4. WH-7 & 9 Classic Series Piping Installation.....................4 12. Setting the Smart Control™........................................... 26 5. Top Down™ TD-Series Piping Installation...............
. REQUIRED COMPONENTS AND ACCESSORIES CHECKLIST MODEL CIRCULATOR ZONE VALVE* SHUTOFF VALVE VACUUM BREAKER RELIEF VALVE THERMAL EXPANSION TANK DRAIN Residential = 5GPM WH SERIES Commercial = 10GPM Except “P” Models *If Circulator not used 3/4” Full Port 4 1 Included or 1” STD Required (See Therm-X-Trol® Sizing Guide) Included 5GPM TD SERIES Except “P” Models *If Circulator not used 3/4” Full Port 4 1 Included or 1” STD Required (See Therm-X-Trol® Sizing Guide)
. WH CLASSIC SERIES PIPING INSTALLATION DOMESTIC WATER PIPING BOILER PIPING 1. Thread the included 3/4” brass tee onto the pipe marked COLD WATER. 1. Plumb the circulator or zone valve on the BOILER SUPPLY line. If using a separate circulator, the pump flange can be mounted directly to the threaded pipe marked BOILER SUPPLY. Alternately, the circulator can be placed anywhere on the boiler supply line. 2. Screw the 3/4” drain valve into the opposite end of the brass tee. 3.
PIPING USING SEPARATE CIRCULATOR PUMP (RECOMMENDED) PIPING USING ZONE VALVE WITH EXISTING HEATING SYSTEM CIRCULATOR -5-
5. TOP DOWN™ TD-SERIES PIPING INSTALLATION 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. Make an 8-inch “heat trap” on the HOT WATER outlet as shown in the diagram. This will reduce standby losses from heat migrating up the piping. 4. When all domestic water piping is complete, open the cold water supply and allow some water to enter the tank.
PIPING USING SEPARATE CIRCULATOR PUMP (RECOMMENDED) PIPING USING ZONE VALVE WITH EXISTING HEATING SYSTEM CIRCULATOR -7-
6. READY-TO-RUN RTR-SERIES PIPING INSTALLATION DOMESTIC WATER PIPING BOILER PIPING 1. Connect the cold water supply to the pipe labeled COLD WATER. 1. Plumb the BOILER SUPPLY line. The circulator and flow check are factory installed 2. Connect the HOT WATER piping to the domestic hot water system. 2. Pipe the BOILER RETURN connection to the boiler return line. 3. Make an 8-inch “heat trap” on the HOT WATER outlet as shown in the diagram.
PIPING MODELS WITH PRE-INSTALLED CIRCULATOR W/INTEGRAL FLOW CHECK -9-
7. WHS PREMIER SERIES PIPING INSTALLATION DOMESTIC WATER PIPING BOILER PIPING 1. Thread one of the included brass tees onto the pipe marked COLD WATER. 1. Plumb the circulator or zone valve on the BOILER SUPPLY line. If using a separate circulator, the pump flange can be mounted directly to the threaded pipe marked BOILER SUPPLY. Alternately, the circulator can be placed anywhere on the boiler supply line. 2. Screw the drain valve into the 3/4" outlet of the brass tee. 3.
PIPING USING SEPARATE CIRCULATOR PUMP (RECOMMENDED) PIPING USING ZONE VALVE WITH EXISTING HEATING SYSTEM CIRCULATOR -11-
8. WIRING ALL SMART CONTROL™ MODELS The Smart Control™ incorporates all the switching and temperature control functions necessary to control the BoilerMate™. The diagram below shows internal wiring and the associated functions. After wiring is complete, insert the white thermistor (sensor) plug into the receptacle at the base of the Smart Control™. Select the plug marked CIRCULATOR or ZONE VALVE based on the application. Zone valves can be slow actuating.
L1 BOILERMATE® JUNCTION BOX L2 ORANGE ORANGE BLUE L8124 A & C 2 1 BLUE VIOLET T T VIOLET WHITE BLACK (PLACE A WIRE NUT OVER EACH WIRE NOT USED) B2 B1 C2 C1 BOILERMATE® CIRCULATOR ZR ZC HONEYWELL L8124 A & C L8124 B & D T T BOILERMATE® JUNCTION BOX LOW LIMIT/ CIRCULATOR HIGH LIMIT B R R B ORANGE ORANGE W BLUE BLUE VIOLET VIOLET B2 C1 B1 WHITE BLACK 1 C2 2 (PLACE A WIRE NUT OVER EACH WIRE NOT USED) BOILERMATE® CIRCULATOR HONEYWELL L8124 B & D L1 L2 L1 L2 BOILERMATE® JUN
BOILERMATE® JUNCTION BOX L8148J T TP W TV ORANGE ORANGE Z BLUE HI LIMIT BLUE B VIOLET R VIOLET WHITE BLACK C1 C2 B1 B2 B3 (PLACE A WIRE NUT OVER EACH WIRE NOT USED) L1 L2 BOILERMATE® CIRCULATOR L1 L2 HONEYWELL L8148 J WITH MILLIVOLT GAS VALVE BOILERMATE® JUNCTION BOX L8148J T TP W TV ORANGE ORANGE Z BLUE HI LIMIT BLUE B VIOLET R VIOLET WHITE BLACK C1 C2 B1 B2 B3 (PLACE A WIRE NUT OVER EACH WIRE NOT USED) L1 L2 BOILERMATE® CIRCULATOR L1 L2 HONEYWELL L8148 J WITH 24 VOLT GAS V
BOILERMATE® JUNCTION BOX 8J48A TV W T TP Z B BLUE C1 C2 L1 B3 B2 B1 ORANGE ORANGE BLUE VIOLET L2 VIOLET WHITE BLACK (PLACE A WIRE NUT OVER EACH WIRE NOT USED) WHITE - RODGERS 8J48A WITH SELF-GENERATING GAS VALVE L1 L2 BOILERMATE® JUNCTION BOX ORANGE ORANGE BLUE L8124 A & C 1 BLUE T T 2 VIOLET VIOLET WHITE BLACK B2 B1 C2 C1 ZR ZC HEATING CIRCULATOR BOILERMATE® CIRCULATOR PRIORITY WIRING HONEYWELL L8124 A & C L8124 B & D T T HIGH LIMIT BOILERMATE® JUNCTION BOX LOW LIMIT/
L1 L2 BOILERMATE® JUNCTION BOX L8148A L1 T L2 ORANGE T ORANGE BLUE HIGH LIMIT 3 BLUE VIOLET B VIOLET R WHITE BLACK C1 C2 B1 B2 BOILERMATE® CIRCULATOR PRIORITY WIRING HONEYWELL L8148A L1 L2 BOILERMATE® JUNCTION BOX ORANGE ORANGE L8148B L1 BLUE T L2 T BLUE VIOLET HIGH LIMIT VIOLET B BLACK WHITE R C1 C2 B1 BOILERMATE® CIRCULATOR B2 PRIORITY WIRING HONEYWELL L8148B BOILERMATE® JUNCTION BOX L8148J T TP W TV ORANGE ORANGE Z HI LIMIT BLUE BLUE B VIOLET R VIOLET W
BOILERMATE® JUNCTION BOX L8148J T W TP Z TV ORANGE ORANGE BLUE BLUE B HI LIMIT VIOLET R VIOLET WHITE BLACK C1 C2 B1 B2 B3 L1 L2 BOILERMATE® CIRCULATOR PRIORITY WIRING HONEYWELL L8148 J WITH MILLIVOLT GAS VALVE L1 L2 BOILERMATE® JUNCTION BOX 8J48A TV W T TP Z B ORANGE C1 B3 B2 B1 L1 HEATING CIRCULATOR C2 ORANGE BLUE BLUE VIOLET L2 VIOLET WHITE BLACK PRIORITY WIRING WHITE-RODGERS 8J48A WITH 24VOLT GAS VALVE (PLACE A WIRE NUT OVER EACH WIRE NOT USED) BOILERMATE® CIRCULATOR B
Typical Multi-Zone Relay Utilizing Post-Purge Feature ORANGE ORANGE BLUE BLUE Thermostat Inputs VIOLET VIOLET Priority or DHW Zone BLACK WHITE Zone Outputs X X T T Smart Control™ L1 L2 120V Supply (PLACE A WIRE NUT OVER EACH WIRE NOT USED) BoilerMate® Circulator Boiler Aquastat Typical Multi-Zone Relay 24V without Post-Purge Feature ORANGE ORANGE BLUE BLUE Thermostat Inputs VIOLET VIOLET Priority or DHW Zone 24V Supply Zone Outputs Smart Control™ (PLACE A WIRE NUT OVER EACH WIRE NOT USED)
WATER SENSOR INSTALLATION (IF EQUIPPED) The Smart Control™ features an error code designed to alert the user to the presence of water on the floor. This is useful to warn of a leaking boiler, water heater, etc., or to alert the owner to a leak in the basement. If equipped with the optional water sensor, follow the installation instructions below: Water Sensor Plug 1.
9. WIRING ALL DIAL CONTROL MODELS (EXCEPT RTR MODELS) Dial Control models utilize a standard dry-contact aquastat with capillary temperature sensor. The dial control contains a make-and-break switch and is suitable for 24V or 120V, 25A Max. CAPILLARY TUBE SENSOR BULB SHAFT WIRE LEADS To wire Dial Control models, select the appropriate diagram from the following pages. If a suitable diagram is not available for your application, please contact AMTROL Tech Support at (401)535-1216.
ZONE VALVES - SCHEMATIC 3 3-WIRE ZONE VALVES PRIORITY W/CIRCULATORS - SCHEMATIC 4 Typical Multi-Zone Relay Thermostat Inputs Priority or DHW Zone Zone Outputs X X T T Boiler Aquastat BoilerMate® Circulator -21- BoilerMate® Thermostat
BOILER CONTROL - SCHEMATIC 5 HONEYWELL L8148E 4 WIRE ZONE VALVE "T" (ON BOILER CONTROL) "T" L2 L1 SMART CONTROL™ JUNCTION BOX ORANGE ORANGE END SWITCH 40VA TRANSFORMER MOTOR BLUE BLUE VIOLET VIOLET 24 VOLT BLACK WHITE (PLACE A WIRE NUT OVER EACH WIRE NOT USED IN THE AMTROL BOILER MATE® JUNCTION BOX.
10. WIRING ALL READY-TO-RUN (RTR) MODELS Ready-To-Run models include a circulator with built-in priority zoning relay. The aquastat is pre-wired and controls the circulator. Line voltage must be supplied and a signal wire must be run to fire the boiler. PR IN 1 2 3 PR OUT LIVE NEUT 4 LINE IN LINE OUT CANCELS ON CALL FOR DHW DHW AQUASTAT FACTORY WIRED DRY CONTACT TO BOILER OR EXTERNAL RELAY CIRCULATOR RELAY OPERATION To wire RTR models, select the appropriate diagram from the following pages.
CIRCULATOR RELAY BOX PR IN 1 2 3 CIRCULATOR RELAY BOX PR OUT LIVE NEUT PR IN 4 1 2 3 PR OUT LIVE NEUT 4 L2 L1 Indirect Aquastat L1 L2 T L2 Indirect Aquastat L1 T B 3 REMOVE JUMPER BETWEEN 1 & 3 B2 HEATING CIRCULATOR C1 C2 L1 L2 HONEYWELL L8148J W/MILLIVOLT GAS VALVE HONEYWELL L8148A OR SIMILAR W/PRIORITY CIRCULATOR RELAY BOX PR IN 1 2 3 CIRCULATOR RELAY BOX PR OUT LIVE NEUT PR IN 4 1 3 2 PR OUT LIVE NEUT 4 L2 L1 Indirect Aquastat L2 L1 Indirect Aquastat THERMOSTATS
11. STARTUP PROCEDURE FOR ALL MODELS 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 to maximize efficiency. If not, check wiring and consult the troubleshooting section in this manual. 4.
12. SETTING THE SMART CONTROL™ The Smart Control™ incorporates multiple features that increase hot water performance and efficiency. All settings are accessed via the MODE button. To change any setting, simply hold the MODE button then tap to cycle through the settings as outlined below. GREEN LIGHT - CIRCULATOR INDICATOR MODE SWITCH READOUT DISPLAY • When power is applied to the unit, the display will show the setpoint temperature (default 120°F).
13. TROUBLESHOOTING SOLUTION PROBLEM No hot water 1. 2. 3. 4. 5. No power to unit Air in heat exchanger loop Faulty circulator or zone valve Faulty BoilerMate™ thermostat Faulty Smart Control™ 6. Boiler inoperable Insufficient hot water 1. 2. 3. 4. Demand exceeds capacity Temperature too low Boiler lacks sufficient output Fouled heat exchanger 5. Insufficient heat exchanger flow 1. Improper plumbing Water too hot and/ or ER2 message on Smart Control™ Noise from BoilerMate® 2. 3. 4. 5.
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15. CLEANING THE BOILERMATE® HEAT EXCHANGER COIL A diminished temperature difference between the boiler water entering and leaving the heat exchanger coil may indicate heat exchanger scale buildup. Water treatment equipment and proper maintenance will help to avoid this problem. To clean a scaled heat exchanger coil proceed as follows: 1. Shut off the cold water supply to the BoilerMate®. 2. Make a note of the temperature control setting on the BoilerMate®, then turn the unit off. 3.
15. 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 notes 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.
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