Amtrol Water Heater whs-series User's Manual
Contents
1. 2 3 4 5 1 Thermal expansion tank undersized or missing 1 Install the properly sized thermal expansion tank 2 Thermal expansion tank set improperly 2 Ensure precharge air pressure matches static water pressure Relief valve dripping toute or opening 3 City pressure too high 3 Install a Pressure Reducing Valve PRV if city pressure is over 80psi 4 System over temperature 4 Determine cause of over temperature condition and correct problem 5 Faulty relief valve 5 Replace relief valve Discolored water 1 Poor water quality 1 Have water tested for contaminants at faucet 2 Sediment or suspended particles 2 Install sediment filter purge unit more often to avoid future problems Boiler will not operate 1 Improper or loose wiring 1 Check connections against wiring diagrams in this manual when calling for 2 Boiler high limit has been reached 2 Boiler will periodically cycle on and off during operation hot water 3 Problem with boiler system 3 Have boiler diagnosed for proper operation Warranty WHS Series and DC Series 10 Year Limited Warranty Residential 5 Year Limited Warranty Commercial Visit www amtrol com for complete warranty details PHCC CONTRACTORS ASSOCIATION 2014 AMTROL Inc 2 AMTROL 1400 Division Road West Warwick RI 02893 USA T 800 426 8765 F 800 293 1519 www amtrol com LOW LEAD JA 5 MADE IN USA Part 9040 534 01 142. PREMIER SERIES INDIRECT FIRED WATER HEATERS INSTALLATION amp OPERATION INSTRUCTIONS EA AMTROL WHS Series Mechanical Control DC Series Mechanical Control PLEASE READ THE FOLLOWING INSTRUCTIONS CAREFULLY INSTALLER LEAVE THIS MANUAL WITH THE OWNER PREMIER PREMIER 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 HAZARDS OBEY ALL SAFETY MESSAGES THAT FOLLOW THIS SYMBOL TO REDUCE THE RISK OF PERSONAL THIS IS THE SAFETY ALERT SYMBOL IT IS USED TO ALERT YOU TO POTENTIAL PERSONAL INJURY AND OTHER INJURY AS WELL AS PROPERTY DAMAGE READ CAREFULLY THE PRODUCT A WARNING INSTALLATION amp 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 DO NOT LIFT OR CARRY WATER HEATER BY A W
3. 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 General Safety Information ADANGER 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 ADANGER 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 A WARNING make your product unsafe In limited circumstances space he
4. 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 Install the T amp 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 A CAUTION the outer tank shell Do not screw pipe hangers or other hardware into the exterior of the tank Boiler Piping 1 4 Plumb the circulator or zone valve on the BOILER SUPPLY line Pipe the BOILER RETURN connection to the boiler return line Be sure the return line is NOT plumbed to A CAUTION 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 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 uti
5. VOID THE PRODUCT WARRANTY c 3 S 5 o lt d o 3 Required Components and Accessories Checklist WHS Models See Chart Full Port ENEN DC Models See Chart Full Port VACUUM BREAKER THERMAL EXPANSION TANK 60 Gal Models 4 4 Gal 150 psig 210 F go Gal Models 4 4 Gal Included Included Included 120 Gal Models 4 4 Gal 80 Gal Models 4 4 Gal 120 Gal Models 4 4 Gal 150 psig 210 F Included 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 10 Pressure Drop FT Double Wall Heat Exchanger Pd 6 Single Wall Heat Exchanger 10 12 Flow GPM If a steel hydropneumatic tank is in place A CAUTION 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 an existing expansion tank and the boiler temperatures are being changed resize the existing diaphragm expansion tank Plumbing Domestic Water Piping 1 2 3 Connect the cold water supply to the connection labeled COLD WATER Connect the HOT WATER piping to the domestic hot water system When all domestic water piping is complete open the cold water supply and allow some water to enter the tank
6. 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 Typical Gas Valves Non Priority 24V Thermostat Input Priority HONEYWELL HONEYWELL R4222D 1013 HONEYWELL R4222D 1013 OR EQUIVALENT R4222D 1013 OR EQUIVALENT DPDT RELAY OR EQUIVALENT DPDT RELAY 2 DPDT RELAY AQUASTAT AQUASTAT WHEN NO ZR TERMINAL IS AVAILABLE GO TO THE SUPPLY SIDE OF THE HI LIMIT Zone Valves 4 Wire AQUASTAT END SWITCH Other Applications Multi Zone Control Boiler Control Input AQUASTAT AQUASTAT DHW ZONE DHW ZONE CIRCULATOR OR ZONE VALVE CIRCULATOR OR ZONE VALVE 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 appea
7. WARNING u Ar 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 A WARNING 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 A CAUTION 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 3 n c EXPLOSION OR RUPTURE HAZARD relief A WARNING 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
8. 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 A WARNING 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 ADANGER 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 A WARNING may over time corrode weaken and burst causing serious or fatal injury leaking or flooding and or property damage To
9. 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 A WARNING 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 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
10. ARNING THE Top COVER WATER HEATER DAMAGE OR PERSONAL INJURY MAY OCCUR IF THE COVER BECOMES DETACHED The heat transfer medium must be water or other A CAUTION 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 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 A CAUTION 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
11. ating can be lost in A WARNING 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 A CAUTION 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 A WARNING thermal expansion tank is required with the water heater and should be installed as set forth in the product installation manual Contact your water supplier or local plumbing inspector for additional information ADANGER 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 ADANGER Electrocution hazard The water heater must be electrically grounded Electrical supply must
12. lizing a zone valve to control the water heater temperature 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 ADANGER EXPLOSION HAZARD Do not install to a high pressure steam boiler greater than 15 psig An explosion could occur Clearance From Combustible Surfaces LEFT SIDE 1 REAR kasa dan eg a aba 1 RIGHT SIDE 1 FLOOR ox 0 ra tee 9 FRONT mantas 1 Recommended Clearance for Servicing VERT bee bids 12 HEAD ROOM 36 RIGHT reme 12 REAR erre 1 FRONT t3 cccn4 dace 30 WHS Models PIPING USING SEPARATE CIRCULATOR PUMP RECOMMENDED Extrol Expanion Tank Boiler System Supply Hot Water Supply Heat Trap System Return Blowdown Tube Weighted Flow Check Shutoff Valve Premier Series Water Heater Drain or Purge Valve Circulator Relief Valve BOILER BOILER Cold Water Suply Therm X Trol Thermal Expansion Tank PIPING USING ZONE VALVE WITH EXISTING HEATING SYSTEM CIRCULATOR Extrol Expanion Tank Boiler System Supply Hot Water Supply Heat Trap Blowdown Tube Weighted Flow Check Shutoff Valve Premier Series Water Heater Drain or Purge Valve Circulator Relief Valve BOILER BOILER Cold Water Suply Therm X Trol Thermal Expansion Tank
13. 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 A WARNING 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 DANGER 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 ADANGER zone Do not connect this unit to an existing heating zone or feed boiler water directly through the coil as dangerous over heating Do not drain this appliance before shutting off the A CAUTION 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 A
14. r 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 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 5 SET TEMPERATURE The control should be set to the minimum temperature consistent with the user s needs This maximizes efficiency and reduces scald potential Painful scalding with possible serious A DANGER and permanent injury can occur if the temperature is set too high or the thermostat is not functioning properly 6 MAINTENANCE The water heater and system should be periodically checked by a licensed professional at least annually and more often as system ages Troubleshooting PROBLEM POSSIBLE CAUSES SOLUTION 1 No power to unit 1 Check circuit breaker boiler emergency switch and boiler reset switch 2 Circulator air bound 2 Purge air Ensure circulator is on Boiler Supply Check air vents No hot water 3 Faulty circulator or zone valve 3 Check ci
15. rculator and zone valve Repair or replace if necessary 4 Faulty control 4 Check continuity Switching circuit should close If not replace control 5 Boiler inoperable 5 Check boiler system Boiler must operate to generate hot water 1 Check sizing based on household size and boiler output 1 Demand exceeds capacity 2 Increase temperature setpoint 2 Temperature too low s S i 3 Set up for priority If problem persists add storage or increase tank size Boiler lacks output for simultaneous heat nol water i 4 Check Boiler Supply Boiler Return during cold startup If difference is less Insufficient hot water 4 Fouled heat exchanger 5 Insufficient heat exchanger flow than 20 F clean heat exchanger as outlined below Install water treatment equipment to prevent recurrence 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 Improper plumbing Temperature set too high Water too hot Temperature sensor bulb not fully inserted Stuck zone valve Flow check valve stuck open a A OO N 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 Reduce temperature setting Re insert temperature sensor bulb Repair or replace Clean repair or replace
16. the rest of your plumbing system USE GLYCOL ONLY WITH DOUBLE AWWARNING 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 AWARNING 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 Priority System Two options are available when wiring the controls of the water heater in the space heating system boiler and distribution elements Non Priority or gt 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 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
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