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INSTALLATION, OPERATION
West Warwick, Rhode Island 02893 & MAINTENANCE
INSTRUCTIONS
®
BOILERMATE
INDIRECT-FIRED WATER HEATERS
MODELS CODES:
MODELS COVERED:
™
P: Packaged with circulator & Smart Control
• WH-7 & 9 Classic Series
™ ™
L: Less Circulator, with Smart Control
• Top Down TD Series
Z: Dial Aquastat
• RTR models
C: High-output commercial exchanger
• WHS Premier Series
DW: Double-wall heat exchanger
RTR: Pre-piped and wired
INSTALLER: LEAVE THIS MANUAL WITH THE OWNER
IMPORTANT G
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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 ........
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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 Circulator not used Required ® TD SERIES Except “P” Models 3/4” Full Port 4 1 Included (See Therm-X-Trol Included or 1” STD Sizin
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4. WH-7 & 9 CLASSIC SERIES PIPING INSTALLATION DOMESTIC WATER PIPING BOILER PIPING 3 1. Plumb the circulator or zone valve on the BOILER SUPPLY 1. Thread the included /4” brass tee onto the pipe marked line. If using a separate circulator, the pump flange COLD WATER. can be mounted directly to the threaded pipe marked BOILER SUPPLY. Alternately, the circulator can be placed 3 2. Screw the /4” drain valve into the opposite end of the brass anywhere on the boiler supply line. tee. 2. Pipe
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PIPING USING SEPARATE CIRCULATOR PUMP (RECOMMENDED) PIPING USING ZONE VALVE WITH EXISTING HEATING SYSTEM CIRCULATOR -5-
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5. TOP DOWN™ TD-SERIES PIPING INSTALLATION can be mounted directly to the threaded pipe marked DOMESTIC WATER PIPING BOILER SUPPLY. Alternately, the circulator can be placed anywhere on the boiler supply line. 1. Connect the cold water supply to the pipe labeled COLD WATER 2. Pipe the BOILER RETURN connection to the boiler return line. 2. Connect the HOT WATER piping to the domestic hot water system. Be sure the return line is NOT plumbed to the suction side of any 3. Make an 8-inch “hea
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PIPING USING SEPARATE CIRCULATOR PUMP (RECOMMENDED) PIPING USING ZONE VALVE WITH EXISTING HEATING SYSTEM CIRCULATOR -7-
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6. READY-TO-RUN RTR-SERIES PIPING INSTALLATION DOMESTIC WATER PIPING BOILER PIPING 1. Connect the cold water supply to the pipe labeled COLD 1. Plumb the BOILER SUPPLY line. The circulator and flow WATER. check are factory installed 2. Connect the HOT WATER piping to the domestic hot water 2. Pipe the BOILER RETURN connection to the boiler return system. line. Be sure the return line is NOT 3. Make an 8-inch “heat trap” on the HOT WATER outlet as plumbed to the suction side of any shown in
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PIPING MODELS WITH PRE-INSTALLED CIRCULATOR W/INTEGRAL FLOW CHECK -9-
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7. WHS PREMIER SERIES PIPING INSTALLATION DOMESTIC WATER PIPING BOILER PIPING 1. Thread the included brass tee onto the pipe marked COLD 1. Plumb the circulator or zone valve on the BOILER SUPPLY WATER. line. If using a separate circulator, the pump flange can be mounted directly to the threaded pipe marked 2. Screw the drain valve into the opposite end of the brass BOILER SUPPLY. Alternately, the circulator can be placed tee anywhere on the boiler supply line. 3. Connect the cold water su
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PIPING USING SEPARATE CIRCULATOR PUMP (RECOMMENDED) PIPING USING ZONE VALVE WITH EXISTING HEATING SYSTEM CIRCULATOR -11-
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™ 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. Therefore, the zone valve sensor co
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® BOILERMATE L1 L2 JUNCTION BOX ORANGE ORANGE BLUE L8124 A & C BLUE VIOLET 1 2 T T VIOLET WHITE BLACK (PLACE A WIRE NUT OVER EACH WIRE NOT USED) ® BOILERMATE B2 B1 CIRCULATOR ZR C2 C1 ZC HONEYWELL L8124 A & C L8124 B & D ® T BOILERMATE T JUNCTION BOX ORANGE HIGH LOW LIMIT/ CIRCULATOR LIMIT ORANGE W BLUE B R BLUE B VIOLET R VIOLET B2 C1 B1 WHITE BLACK C2 1 2 (PLACE A WIRE NUT OVER EACH WIRE NOT USED) ® BOILERMATE CIRCULATOR HONEYWELL L8124 B & D L1 L2 L1 L2
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® BOILERMATE JUNCTION BOX L8148J ORANGE T W TV ORANGE TP Z BLUE BLUE HI B LIMIT VIOLET R VIOLET WHITE BLACK C1 C2 (PLACE A WIRE NUT OVER B2 B3 B1 L1 L2 EACH WIRE NOT USED) ® BOILERMATE CIRCULATOR L1 L2 HONEYWELL L8148 J WITH MILLIVOLT GAS VALVE ® BOILERMATE JUNCTION BOX L8148J ORANGE W TV T ORANGE Z TP BLUE BLUE HI B LIMIT VIOLET R VIOLET WHITE BLACK C1 C2 (PLACE A WIRE NUT OVER B1 B2 B3 L1 L2 EACH WIRE NOT USED) ® BOILERMATE CIRCULATOR L1 L2 HONEYWELL
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® BOILERMATE JUNCTION BOX 8J48A ORANGE TV W T ORANGE Z B TP BLUE BLUE C1 C2 VIOLET L1 B1 B2 B3 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 BLUE VIOLET 1 2 T T VIOLET WHITE BLACK B2 B1 ZR ZC C2 C1 ® BOILERMATE CIRCULATOR PRIORITY WIRING HEATING CIRCULATOR HONEYWELL L8124 A & C L8124 B & D ® T T BOILERMATE JUNCTION BOX HIGH
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L1 L2 ® BOILERMATE JUNCTION BOX L8148A ORANGE L1 L2 T T ORANGE BLUE HIGH 3 LIMIT BLUE VIOLET B VIOLET WHITE R BLACK C1 C2 B1 B2 ® PRIORITY WIRING BOILERMATE CIRCULATOR HONEYWELL L8148A L1 L2 ® BOILERMATE JUNCTION BOX ORANGE ORANGE L8148B BLUE BLUE L1 L2 T T VIOLET HIGH VIOLET LIMIT WHITE B BLACK R ® BOILERMATE C1 C2 B1 B2 CIRCULATOR PRIORITY WIRING HONEYWELL L8148B ® BOILERMATE JUNCTION BOX L8148J ORANGE T W TV ORANGE Z TP BLUE BLUE HI B LIMIT VIOLE
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® BOILERMATE JUNCTION BOX L8148J ORANGE T W TV ORANGE Z TP BLUE BLUE HI B VIOLET LIMIT R VIOLET WHITE BLACK C1 C2 B1 B2 B3 L1 L2 PRIORITY WIRING ® BOILERMATE HONEYWELL L8148 J CIRCULATOR WITH MILLIVOLT GAS VALVE L1 L2 ® BOILERMATE JUNCTION BOX 8J48A ORANGE TV W T ORANGE HEATING TP Z B BLUE CIRCULATOR C1 BLUE C2 VIOLET L1 B3 B1 B2 L2 VIOLET WHITE BLACK (PLACE A WIRE NUT OVER EACH WIRE NOT USED) PRIORITY WIRING WHITE-RODGERS 8J48A ® BOILERMATE WITH 24VOL
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Typical Multi-Zone Relay ORANGE Utilizing Post-Purge Feature ORANGE BLUE BLUE Thermostat Inputs VIOLET VIOLET Priority or DHW Zone BLACK WHITE Zone Outputs Smart Control™ X X L1 L2 (PLACE A WIRE NUT OVER EACH WIRE NOT USED) 120V Supply T T ® BoilerMate Boiler Aquastat Circulator Typical Multi-Zone Relay ORANGE 24V without Post-Purge Feature ORANGE BLUE BLUE Thermostat VIOLET Inputs VIOLET Priority or DHW Zone BLACK 24V Supply WHITE Zone Outputs Smart
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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. If the sensor will be used to detect a water heater leak, the proper placement is in a drip pan as required in the warning se
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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. Always d
