Instructions / Assembly

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BOILERMATE

INDIRECT-FIRED WATER HEATERS

INSTALLATION & OPERATION INSTRUCTIONS

NOTE: A properly sized thermal

expansion tank is required and should

be installed in accordance with the

product installation manual.

NOTE: The thermostat is adjusted to

120°F when shipped from the factory.

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.

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.

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.html

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.

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.

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.

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 medium must be limited to 30 PSIG by an

approved safety or relief valve.

Do not expose Product to freezing temperatures or

temperatures in excess of the maximum rated

operating temperature.

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.

Models WH (Mechanical Control & Digital Control)

Models CH (Mechanical Control)

Summary of content (12 pages)

PAGE 1
BOILERMATE ® INDIRECT-FIRED WATER HEATERS INSTALLATION & OPERATION INSTRUCTIONS Models WH (Mechanical Control & Digital Control) Models CH (Mechanical Control) NOTE: A properly sized thermal expansion tank is required and should be installed in accordance with the product installation manual. NOTE: The thermostat is adjusted to 120°F when shipped from the factory. NOTE: Inspect for shipping damage and notify freight carrier or store where purchased immediately if damage is present.
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SCALDING HAZARD. If the water temperature is over 120°F, household members can suffer serious or fatal scalding and painful and permanent injury. Electrocution hazard. The water heater must be electrically grounded in accordance with local codes or, in the absence of local codes, with the National Electrical Code, ANSI/ NFPA 70. 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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PLEASE READ THE FOLLOWING INSTRUCTIONS CAREFULLY IMPORTANT GENERAL SAFETY INFORMATION ADDITIONAL SPECIFIC SAFETY ALERTS APPEAR IN THE FOLLOWING INSTRUCTIONS. Pre-Installation 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.
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Installation - Domestic Water Piping CH Models PIPING USING DEDICATED CIRCULATOR PUMP (RECOMMENDED) 1. Connect the cold water supply to the connection labeled COLD WATER. 2. Connect the HOT WATER piping to the domestic hot water system. To Heating Zones 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. Cold Water Supply Therm-X-Trol® Boiler Supply 4.
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Installation - Boiler Piping 1. Plumb the circulator or zone valve on the BOILER SUPPLY line. Zone Valves 2. Pipe the BOILER RETURN connection to the boiler return line. Be sure the return line is NOT plumbed to the suction side of any 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-Wire AQUASTAT 3.
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Installation - Digital Control Wiring 1. Ensure the control 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.
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Installation - Digital Control Set-Up Mode Indicators After wiring per the appropriate diagram in this manual, insert the white temperature sensor (thermistor) plug into the receptacle at the base of the digital control. 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.
PAGE 8
Start-Up 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.
PAGE 9
Replacement Parts Description ID Heat Exchanger Replacement, WH-41 Single Wall Heat Exchanger Replacement, WH-41 Double Wall 1 Heat Exchanger Replacement, CH-41 Single Wall Heat Exchanger Replacement, CH-80 Double Wall WH Series CH Series 2700-5000 - 2700-5002 - - 2703R003 - 2702R002 Mounting Panel Only, Mechanical Control 2 2704R498 - Mounting Panel Only, Digital Control 3 2704R525 - Mechanical Temperature Control 4 2704-093 Digital Temperature Control w/Panel 5 940R101 - Temp
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