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INSTALLATION & OPERATION INSTRUCTIONS
™
HYDROMAX
INDIRECT-FIRED WATER HEATERS
1400 Division Road, West Warwick, RI 02893 T: 401.884.6300 F: 401.885.2567 www.amtrol.com
PLEASE READ THE FOLLOWING INSTRUCTIONS CAREFULLY
INSTALLER: LEAVE THIS MANUAL WITH THE OWNER
Models Covered:
HM-41Z & HM-80Z (Mechanical Control)
HM-41L & HM-80L (Ener-G-NET™ Digital Control)
IMPORTANT GENERAL SAFETY INFORMATION - ADDITIONAL SPECIFIC SAFETY ALERTS APPEAR IN THE
FOLLOWING INSTRUCTIONS.
DO NOT LIFT OR CAR
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1. Table Of Contents 2. Pre-Installation Checklist ............................................... 2 7. Mechanical Aquastat Wiring .......................................... 8 3. Required Components and Accessories Checklist ....... 3 8. Startup Procedure ......................................................... 9 ™ 4. HYDROMAX Plumbing ............................................... 4 9. Troubleshooting ............................................................. 9 ™ 5. Ener-G-NET Wiring .....
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3. Required Components And Accessories Checklist THERMAL CIRCULATOR SHUTOFF MODEL ZONE VALVE RELIEF VALVE EXPANSION PERFORMANCE VALVES TANK HM-41 5 GPM @ 7 FT 3/4” Full Port 4 Included 2.0 Gallon HM-80 5 GPM @ 7 FT 3/4” Full Port 4 Included 4.4 Gallon If a steel hydropneumatic tank is in place, 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 exis
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™ 4. HYDROMAX Plumbing Do not drill, puncture or otherwise DOMESTIC WATER PIPING penetrate the steel outer tank shell. 1. Connect the cold water supply to the pipe labeled Do not screw pipe hangers or other hardware into the COLD WATER. exterior of the tank. 2. Connect the HOT WATER piping to the domestic hot BOILER PIPING water system. 1. Plumb the circulator or zone valve on the BOILER SUPPLY line. 3. When all domestic water piping is complete, open the cold water supply and allow so
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™ 5. Ener-G-NET Wiring Ener-G-NET incorporates all of the temperature sensing and control necessary for HYDROMAX™ operation. Built-in switching relays may be wired to operate the boiler control and circulator pump or zone valve. The diagram below illustrates these internal switching functions. Examples of common wiring scenarios are provided on the following page. Normally Open ORANGE Close on call for hot water Post-Purge function { Front Panel ORANGE Control BLUE Normally Open Close on call
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™ Ener-G-NET Wiring 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. NOTE: Ensure the Ener-G-NET installation is within the following application and operating parameters: • Ambient temperature from 38° to 125°F • Relative humid ity ranging from 20% to 90% (non-condensing). • Boiler load rating up to 15A resistiv
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™ 6. Ener-G-NET Control Setup & Adjustment Mode Indicators Ener-G-NET features two distinct programming areas: User Modes and Installer Settings. User Modes consist of three end-user functional User modes, while Installer Settings are primarily accessed upon initial setup Modes LED to specify critical operating parameters. Ener-G-NET factory defaults Display allow traditional operation suitable for most homes. To optimize the control setup, reference the tables below. Installer Settings
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7. 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 Gas Valves (Non-Priority) Typical Oil Burner (Non-Priority) 24V Thermostat Input (Priority) HONEYWELL HONEYWELL R4222D 1013 HONEYWELL R4222D 1013 W OR EQUIVALENT R4222D 1013 OR EQUIVALENT DPDT RELAY OR EQUIVALENT T DPDT RELA
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8. 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.
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10. General Safety Information SCALDING HAZARD. If the water temperature is This Product, like most Products under pressure, over 120°F, household members can suffer serious may over time corrode, weaken and burst or explode, or fatal scalding and painful and permanent injury. • The Consumer causing serious or fatal injury, leaking or flooding and/or property damage. Products Safety Commission recommends an initial setting of 120°F, but To minimize risk, a licensed professio
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11. REPLACEMENT PARTS Description ID HM-41 Models HM-80 Models Heat Exchanger Replacement Kit 1 2713R002 2712R002 Top Cover Half (2 Required) 2 2704R512 2704R512 Mounting Panel, Digital Control 3 2704R525 2704R525 Mounting Panel, Mechanical Control 4 2704R498 2704R498 Ener-G-NET™ Digital Temperature Control 5 940R2 940R2 Temperature Sensor (Thermistor) - 2704-259 2704-259 Water Sensor - 2704-495 2704-495 Mechanical Temperature Control 6 2704-093 2704-093 Universal 10K Sensor Kit - 2704-529 2704-
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1400 Division Road, West Warwick, RI 02893 T: 401.884.6300 F: 401.885.2567 www.amtrol.com HYDROMAX, Ener-G-NET, AMTROL, AMTROL logo, Therm-X-Trol, and EXTROL are registered trademarks of AMTROL Inc. and affiliates in the U.S. and elsewhere. All rights reserved. 9040-694 (10/11)
