Install Instructions

ManualsBrandsAmtrol ManualsIndirect Water Heaters80 Gallon CH-80ZDW-B BoilerMate Champion Series Indirect-Fired Water Heater

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 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 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.

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.

West Warwick, Rhode Island 02893

INSTALLATION, OPERATION

& MAINTENANCE

INSTRUCTIONS

All Champion Series

™

Part #: 9040-678 (07/09)

Champion Series

™

INDIRECT-FIRED WATER HEATER

Summary of content (16 pages)

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West Warwick, Rhode Island 02893 INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS Champion Series™ INDIRECT-FIRED WATER HEATER All Champion Series™ 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.
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1. TABLE OF CONTENTS 2. Pre-Installation Checklist...............................2 6. Wiring.............................................................8 3. Required Components and Accessories Checklist....................................3 7. Startup Procedure For All Models...............10 8. Troubleshooting...........................................11 4. CH-41Z/CH80Z Piping Installation................4 9. Replacement Parts.......................................12 5. CH-41BZ Piping Installation.....
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. REQUIRED COMPONENTS AND ACCESSORIES CHECKLIST MODEL OPTION CIRCULATOR ZONE VALVE* SHUTOFF VALVE VACUUM BREAKER RELIEF VALVE THERMAL EXPASION TANK DRAIN CH-41 CH-41 CH-80 Z BZ Z 4GPM *If Circulator not used 3/4” Full Port or 1” STD 4 1 Included Required (See Therm-X-Trol® Sizing Guide) Included ALL INSTALLATIONS REQUIRE TEFLON® SEALING TAPE OR PIPE DOPE FOR THREADED JOINTS. SEE HEAT EXCHANGER PRESSURE DROP CHART TO DETERMINE PUMP HEAD REQUIREMENTS.
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. CH-41Z/CH-80Z PIPING INSTALLATION DOMESTIC WATER PIPING 1. Connect the cold water supply to the pipe labeled COLD WATER Do not apply heat to this fitting when making sweat connections to heater. Sweat tubing to adapter before fitting adapter to cold water inlet of heater. It is imperative that no heat be applied to the cold water inlet, as it contains a nonmetallic dip tube. 2. Connect the HOT WATER piping to the domestic hot water system. 3.
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PIPING USING DEDICATED CIRCULATOR PUMP (RECOMMENDED) PIPING USING ZONE VALVE WITH EXISTING HEATING SYSTEM CIRCULATOR -5-
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5. CH-41BZ CHAMPION SERIES PIPING INSTALLATION DOMESTIC WATER PIPING BOILER PIPING 1. Thread the included 3/4” brass tee onto the pipe marked COLD WATER. 2. Screw the tee. 3/4” drain valve into the opposite end of the brass 3. Connect the cold water supply to the remaining port on the brass tee. 4. Temporarily attach the top tee fitting (with o-ring face seal) to the union nut on top of the tank. Test fit the piping near the tee before soldering.
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CH-41BZ PIPING USING SEPARATE CIRCULATOR PUMP (RECOMMENDED) PIPING USING ZONE VALVE WITH EXISTING HEATING SYSTEM CIRCULATOR -7-
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6. WIRING CH-41Z and CH-80Z options utilize a standard dry-contact aquastat with capillary temperature sensor. The dial control contains a make-and-break switch and is suitable for 24V. CH-41BZ options 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.
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ZONE VALVES - SCHEMATIC 3 “T” BoilerMate® THERMOSTAT BLACK 1 2 WHITE “T” “T” (ON BOILER CONTROL) END SWITCH L1 (HOT) L2 MOTOR FROM BOILER CONTROL BoilerMate® THERMOSTAT (ON BOILER CONTROL) 3 “T” “A” BLACK 24 VOLT WHITE L1 (HOT) L2 “B” 24 VOLT Typical Multi-Zone Relay Thermostat Inputs BoilerMate® Thermostat Priority or DHW Zone Zone Outputs X X T T Boiler Aquastat BoilerMate® Circulator -9- FROM BOILER CONTROL
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7. STARTUP PROCEDURE FOR ALL MODELS 4. CHECK OPERATION: The BoilerMate® will begin to heat. Depending upon the size of the BoilerMate®, 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. 1.
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7. TROUBLESHOOTING PROBLEM No hot water POSSIBLE CAUSES SOLUTION 1. No power to unit 1. Check circuit breaker, boiler emergency switch and boiler reset switch. 2. Purge air. Ensure circulator is on Boiler Supply. Check air vents. 3. Check circulator and zone valve. Repair or replace if necessary. 4. Check continuity while rotating knob. Circuit should open and close. 5. Check boiler system. Boiler must operate to generate hot water. 2. Air in heat exchanger loop 3. Faulty circulator or zone valve 4.
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9. REPLACEMENT PARTS Number Description 1* Heat Exchanger w/Gasket (CH41Z) 2 Hot Water Outlet Tee Dip Tube (CH-41Z only) 3 Dip Tube (CH-80Z only) 4 Bottom Drain 5 Dial Aquastat 6 Safety Relief Valve 7 Top Cap Assembly (CH-41Z & CH-80Z) 8* CH-41BZ Coil 9* CH-80Z Coil Part Number 2703R003 9403R123 2703R001 2702R001 9340R160 2704-093 2700R116 2704R007 2708R003 2702R002 * Not shown. 5 1 6 7 2 3 To obtain replacement parts, contact the installer or place of purchase.
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10. 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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West Warwick, Rhode Island 02893 BoilerMate, AMTROL, AMTROL logo, Therm-X-Trol, Radiant EXTROL, Champion and EXTROL are registered trademarks of AMTROL Inc. and affiliates in the U.S. and elsewhere. All rights reserved.