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West Warwick, Rhode Island 02893
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.
Part #: 9040-678 (07/09)
INSTALLATION, OPERATION
Champion Series
All Champion Series
& MAINTENANCE
INSTRUCTIONS
™
™
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Related Manuals for Amtrol Champion CH-41Z
Summary of Contents for Amtrol Champion CH-41Z
- Page 1 INSTALLATION, OPERATION & MAINTENANCE West Warwick, Rhode Island 02893 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.
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Page 2: Table Of Contents
1. TABLE OF CONTENTS 2. Pre-Installation Checklist ......2 6. Wiring ............8 3. Required Components and 7. Startup Procedure For All Models ....10 Accessories Checklist ........3 8. Troubleshooting ..........11 4. CH-41Z/CH80Z Piping Installation ....4 9. Replacement Parts ........12 5. CH-41BZ Piping Installation ......6 10. -
Page 3: Required Components And Accessories Checklist
SEE HEAT EXCHANGER PRESSURE DROP CHART TO DETERMINE PUMP HEAD REQUIREMENTS. Heat Exchanger Pressure Drop Use this chart to select the proper circulator for your BoilerMate ® Flow (GPM) If a steel hydropneumatic tank is in place, AMTROL recommends replacing it with a ® properly sized EXTROL or Radiant EXTROL expansion tank. -
Page 4: Ch-41Z/Ch80Z Piping Installation
CH-41Z/CH-80Z PIPING INSTALLATION DOMESTIC WATER PIPING Note: No valve is to be placed between the T&P relief valve and the tank. Note: Valves for reducing point of use temperature by 1. Connect the cold water supply to the pipe labeled COLD mixing cold and hot water are available. - Page 5 PIPING USING DEDICATED CIRCULATOR PUMP (RECOMMENDED) PIPING USING ZONE VALVE WITH EXISTING HEATING SYSTEM CIRCULATOR...
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Page 6: Ch-41Bz Piping Installation
5. CH-41BZ CHAMPION SERIES PIPING INSTALLATION DOMESTIC WATER PIPING BOILER PIPING 1. Thread the included ” brass tee onto the pipe marked 1. Plumb the circulator or zone valve on the BOILER SUPPLY COLD WATER. line. If using a separate circulator, the pump flange 2. - Page 7 CH-41BZ PIPING USING SEPARATE CIRCULATOR PUMP (RECOMMENDED) PIPING USING ZONE VALVE WITH EXISTING HEATING SYSTEM CIRCULATOR...
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Page 8: Wiring
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 disconnect power before wiring the control. Ensure that the proper conduit and connectors are used per your local code. In lieu of local code, the National Electric Code (NEC) should be followed. - Page 9 ZONE VALVES - SCHEMATIC 3 “T” “T” (ON BOILER CONTROL) BoilerMate ® THERMOSTAT END SWITCH BLACK (HOT) MOTOR FROM BOILER CONTROL BoilerMate ® WHITE THERMOSTAT “T” (ON BOILER CONTROL) “T” “A” BLACK WHITE 24 VOLT FROM BOILER (HOT) CONTROL “B” 24 VOLT Typical Multi-Zone Relay Thermostat...
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Page 10: Startup Procedure For All Models
7. STARTUP PROCEDURE FOR ALL MODELS 1. PURGE HEAT EXCHANGER: The heat exchanger 4. CHECK OPERATION: The BoilerMate will begin to ® should be free of large air pockets to allow the heat. Depending upon the size of the BoilerMate ®... -
Page 11: Troubleshooting
7. TROUBLESHOOTING PROBLEM POSSIBLE CAUSES SOLUTION 1. No power to unit 1. Check circuit breaker, boiler emergency switch and boiler reset switch. 2. Air in heat exchanger loop 2. Purge air. Ensure circulator is on Boiler Supply. Check air vents. No hot water 3. -
Page 12: Replacement Parts
Safety Relief Valve 2700R116 Top Cap Assembly (CH-41Z & CH-80Z) 2704R007 CH-41BZ Coil 2708R003 CH-80Z Coil 2702R002 * Not shown. To obtain replacement parts, contact the installer or place of purchase. Technical support is available by calling AMTROL at (401) 535-1216. -12-... -
Page 13: General Safety Information
Current copies of the Product manual This can cause overheating and result in serious or fatal scalding. can be viewed at www.amtrol.com. Use proper safety equipment when installing. SCALDING HAZARD. If the thermostat is not working properly or if this product is not EXPLOSION HAZARD. - Page 16 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 Part #: 9040-678 (07/09) in the U.S. and elsewhere. All rights reserved.