Amtrol Top Down manual

INSTALLER: LEAVE THIS MANUAL WITH THE OWNER IMPORTANT GENERAL SAFETY INFORMATION - ADDITIONAL SPECIFIC SAFETY ALERTS APPEAR IN THE FOLLOWING INSTRUCTIONS. READ CAREFULLY THE PRODUCT INSTALLATION, OPERATING AND MAINTENANCE MANUAL. FAILURE TO FOLLOW THE INSTRUCTIONS AND WARNINGS IN THE MANUAL MAY RESULT IN SERIOUS OR FATAL INJURY AND/OR PROPERTY DAMA[...]

-2- 1. TABLE OF CONTENTS 2. Pre-Installation Checklist ................................................. 2 3. Required Components and Accessories Checklist ......... 3 4. WH-7 & 9 Classic Series Piping Installation .................... 4 5. Top Down™ TD-Series Piping Installation ...................... 6 6. Ready-To-Run RTR-Series Piping Inst[...]

-3- 3. REQUIRED COMPONENTS AND ACCESSORIES CHECKLIST SHUTOFF VACUUM RELIEF THERMAL EXPANSION MODEL CIRCULATOR ZONE VALVE* VALVE BREAKER VALVE TANK DRAIN Residential = 5GPM *If Circulator not used Required WH SERIES Commercial = 10GPM 3/4” Full Port 4 1 Included (See Therm-X-Trol ® Included Except “P” Models or 1” STD Sizing Guide) 5GPM *If[...]

-4- 4. WH-7 & 9 CLASSIC SERIES PIPING INSTALLATION DOMESTIC WATER PIPING 1. Thread the included 3 / 4 ” brass tee onto the pipe marked COLD WATER. 2. Screw the 3 / 4 ” dra in va lve in to th e opp osi te en d of th e bra ss tee. 3. Connect th e col d wat er supply to the r emaini ng po rt on the brass tee. 4. Temporarily attach the top tee [...]

-5- PIPING USING SEPARATE CIRCULATOR PUMP (RECOMMENDED) PIPING USING ZONE VALVE WITH EXISTING HEATING SYSTEM CIRCULATOR[...]

-6- 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. T his will reduce st andby losses fr om heat migrating up the pipi[...]

-7- PIPING USING SEPARATE CIRCULATOR PUMP (RECOMMENDED) PIPING USING ZONE VALVE WITH EXISTING HEATING SYSTEM CIRCULATOR[...]

-8- 6. READY-TO-RUN RTR-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. T his will reduce st andby losses fr om heat migrating up the p[...]

-9- PIPING MODELS WITH PRE-INSTALLED CIRCULATOR W/INTEGRAL FLOW CHECK[...]

-10- 7. WHS PREMIER SERIES PIPING INSTALLATION DOMESTIC WATER PIPING 1. Thread the includ ed brass tee onto the pipe mar ked COLD WATER. 2. Screw the drain valve into the opposite end of the brass tee 3. Connect th e col d wat er supply to the r emaini ng po rt on the brass tee 4. Thread the includ ed T&P Safety Relief Valve into the offset 3 /[...]

-11- PIPING USING SEPARATE CIRCULATOR PUMP (RECOMMENDED) PIPING USING ZONE VALVE WITH EXISTING HEATING SYSTEM CIRCULATOR[...]

-12- 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 Sma[...]

-13- 1 2 T T L1 L2 L8124 A & C ZC ZR B2 C1 B1 C2 BOILERMA TE ® CIRCULA TOR BOILERMA TE ® JUNCTION BOX (PLACE A WIRE NUT OVER EACH WIRE NOT USED) HONEYWELL L8124 A & C ORANGE ORANGE BLUE BLUE VIOLET VIOLET WHITE BLACK BOILERMA TE ® JUNCTION BOX (PLACE A WIRE NUT OVER EACH WIRE NOT USED) ORANGE ORANGE BLUE BLUE VIOLET VIOLET WHITE BLACK HO[...]

-14- HONEYWELL L8148 J WITH MILLIVOL T GAS V A L VE BOILERMA TE ® JUNCTION BOX (PLACE A WIRE NUT OVER EACH WIRE NOT USED) ORANGE ORANGE BLUE BLUE VIOLET VIOLET WHITE BLACK BOILERMA TE ® CIRCULA TOR L1 L2 L8148J C1 C2 L1 L2 B1 B2 B3 B R T W TV TP Z HI LIMIT HONEYWELL L8148 J WITH 24 VOL T GAS V A L VE BOILERMA TE ® JUNCTION BOX (PLACE A WIRE NUT [...]

-15- WHITE - RODGERS 8J48A WITH SELF-GENERA TING GAS VA L VE 8J48A BOILERMA TE ® JUNCTION BOX ORANGE ORANGE BLUE BLUE VIOLET VIOLET WHITE BLACK (PLACE A WIRE NUT OVER EACH WIRE NOT USED) B1 B2 TV W T TP Z B C1 C2 L2 L1 B3 L8124 A & C 2 1 ZC ZR B2 B1 C2 C1 T T BOILERMA TE ® CIRCULA TOR PRIORITY WIRING HONEYWELL L8124 A & C L1 L2 BOILERMA T[...]

-16- BOILERMA TE ® CIRCULA TOR BOILERMA TE ® JUNCTION BOX ORANGE ORANGE BLUE BLUE VIOLET VIOLET WHITE BLACK L8148A L2 L1 C1 C2 B1 B2 3 T B R T L1 L2 PRIORITY WIRING HONEYWELL L8148A HIGH LIMIT PRIORITY WIRING HONEYWELL L8148B B R HIGH LIMIT BOILERMA TE ® CIRCULA TOR BOILERMA TE ® JUNCTION BOX ORANGE ORANGE BLUE BLUE VIOLET VIOLET WHITE BLACK L1[...]

-17- PRIORITY WIRING HONEYWELL L8148 J WITH MILLIVOL T GAS V A L VE L8148J BOILERMA TE ® CIRCULA TOR BOILERMA TE ® JUNCTION BOX ORANGE ORANGE BLUE BLUE VIOLET VIOLET WHITE BLACK HI LIMIT T TV W TP Z B B1 B2 C1 C2 L2 L1 B3 R L1 L2 PRIORITY WIRING WHITE-RODGERS 8J48A WITH 24VOL T GAS V A L VE BOILERMA TE ® CIRCULA TOR BOILERMA TE ® JUNCTION BOX ([...]

-18- T T X X Boiler Aquastat Zone Outputs Priority or DHW Zone Thermostat Inputs T ypical Multi-Zone Relay Utilizing Post-Purge Feature Smart Control™ ORANGE ORANGE BLUE BLUE VIOLET VIOLET BLACK WHITE L1 L2 120V Supply BoilerMate ® Circulator (PLACE A WIRE NUT OVER EACH WIRE NOT USED) T ypical Multi-Zone Relay 24V without Post-Purge Feature T T [...]

The Smart Control™ features an error code designed to alert the user to the presence of water on the oor . 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: W ater Sensor Plug 1. If the senso[...]

-20- 9. WIRING ALL DIAL CONTROL MODELS (EXCEPT RTR MODELS) Dial Control models utilize a standard dry-cont act aquastat with capillary temperat ure sensor. The dial control contains a make-and-break switch and is suitable for 24V or 120V, 25A Max. To wire Dial Control models, select the appropriate diagram from the following pages. If a suitable di[...]

-21- T T X X Boiler Aquastat Zone Outputs Priority or DHW Zone Thermostat Inputs T ypical Multi-Zone Relay BoilerMate ® Circulator BoilerMate ® Thermostat PRIORITY W/CIRCULATORS - SCHEMATIC 4 ZONE VALVES - SCHEMATIC 3 3-WIRE ZONE VALVES[...]

-22- BOILER CONTROL - SCHEMATIC 5 HONEYWELL L8148E ORANGE ORANGE BLUE BLUE VIOLET VIOLET BLACK WHITE SMART CONTROL™ JUNCTION BOX (PLACE A WIRE NUT OVER EACH WIRE NOT USED IN THE AMTROL BOILER MA TE ® JUNCTION BOX.) TRANSFORMER 4 WIRE ZONE VA LV E L1 L2 40VA 24 VOL T L1 L2 NOTE: T AKE L1 AND L2 OFF THE BOILER CONTROL "T" "T" ([...]

-23- Ready- To-Run models include a circula tor with built-in priority zoning relay. The aquastat is pre-w ired and controls the circulator. Line voltage must be supplied and a signal wire must be run to fire the boiler. To wire RTR models, select the appropriate diagram from the following pages. If a suitable diagram is not available for your appl[...]

-24- CIRCULA TOR RELA Y BOX 1 234 C1 C2 Indirect A quastat LIVE NEUT PR OUT PR IN L1 L2 L1 L2 T T HEA TING CIRCULA TOR REMOVE JUMPER BETWEEN 1 & 3 3 HONEYWELL L8148A OR SIMILAR W/PRIORITY CIRCULA TOR RELA Y BOX LIVE NEUT PR OUT PR IN 123 4 L1 L2 Indirect A quastat L1 L2 B2 B HONEYWELL L8148J W/MILLIVOL T GAS VA L V E WHITE RODGERS 8J48A W/24V G[...]

-25- 11. STARTUP PROCEDURE FOR ALL MODELS 1. PURGE HEAT EXCHANGER: The heat exchanger should be free of large air pockets to allow the circul ator to operate properly . Using the diagram below as a g uide, iso late the boile r return line and flu sh the loop until large air pock ets are purged. After this, the air el imination equipment will collec[...]

-26- GREEN LIGHT - CIRCULATOR INDICATOR MODE SWITCH READOUT DISPLAY 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. • When power is appl[...]

-27- 1. No power to unit 2. Air in heat exchanger loop 3. Faulty circulator or zone valve 4. Faulty BoilerMate™ thermostat 5. Faulty Smart Control™ 6. Boiler inoperable 1. Demand exceeds capacity 2. Temperature too low 3. Boiler lacks sufficient output 4. Fouled heat exchanger 5. Insufficient heat exchanger flow 1. Improper plumbing 2. Temperat[...]

-28- WH-7, 41 WHS 60 & 80 WHS 120 WHS 60 & 80 WHS 120 and 9 Series TD-7 Series TD-7 RTR TD-80 Series Residential Residential Commercial Commercial Single Wall Heat Exchanger w/Gasket and Nuts 2700-5000 2700-5005 2700-5007 2700-5008 2775-82 2775-81 2700-5001 2700-5001 Double Wall Heat Exchanger w/Gasket & Nuts 2700-5002 2700-5006 N/A N/A[...]

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. M[...]

-30- 15. GENERAL SAFETY INFORMATION SCALDING HAZARD . If the water temperature is over 120°F, household mem ber s ca n su ffe r ser ious or fata l sc al din g and pa inful and permanent injury. • The Consumer Products Saf ety Com mis sio n rec ommen ds an initia l setti ng of 12 0°F , but notes a slo wer resp ons e tim e of infan ts, aged , dis[...]

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West Warwick, Rhode Island 02893 Part #: 9040-586 (07/08) Boiler Mate, AMTROL, AMTROL logo, Therm-X-T rol, Radiant EXTROL and EXTROL are r egistered trademarks of AMTROL Inc. and affiliates. All rights reserved.[...]