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15. 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.  •  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.

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 make your product unsafe. 

CALIFORNIA  PROPOSITION  65 

WARNING!  WARNING:  This  product 

contains a chemical known by the State 

of  California  to  cause  cancer  and  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

In limited circumstances, space heating 

can  be  lost  in  the  home  with  unit 

utilizing  priority  mode.    Any  demand  for  space  heating  is 

postponed  until  the  Boiler  Mate

®

  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, 

AMTROL

®

 

recommends 

replacing  it  with  a  properly  sized  EXTROL

®

  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 EXTROL

®

 or Radiant EXTROL

®

 expansion tank 

and  the  boiler  temperatures  are  being  changed,  resize  the 

EXTROL

®

 or Radiant EXTROL

®

 expansion tank.

If  installing  on  city  water  supply  a 

properly  sized  THERM-X-TROL

®

  is 

required with the BoilerMate

® 

 and should be installed as set 

fo rth  in  the  THERM-X-TROL

®

  product  installation  manual. 

Contact  your  water  supplier  or  local  plumbing  inspector  for 

additional information.

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.

Electrocution hazard.  The BoilerMate

®

 

must be electrically grounded. Electrical 

supply must 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  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  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.

EXPLOSION HAZARD.  The pressure of 
the heat transfer medium must be limited 

to a maximum of 30 psig by an approved safety or relief valve 
on your boiler.  The BoilerMate

®

 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,  may  over  time  corrode, 

weaken and burst or explode, causing serious or fatal injury, 
leaking or flooding and/or property damage.  To 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.

EXPLOSION OR RUPTURE HAZARD. 
A  relief  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.    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  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 zone.  Do not connect this unit to 

an existing heating zone or feed boiler water directly through 
the coil as dangerous over-heating will result.

Do  not  drain  this  appliance  before 
shutting  off  the  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 

HEAT 

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 moitored for leakage.

Summary of Contents for BoilerMate RTR

Page 1: ...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 m...

Page 2: ...nd also adversely affect its performance M Wiring Options Select either a Non Priority or Priority System Two options are available when wiring the controls of the BOILERMATE in the space heating syst...

Page 3: ...or not used Required WHS SERIES Commercial 10GPM 3 4 Full Port 4 1 Included See Therm X Trol Included Except P Models or 1 STD Sizing Guide ALL INSTALLATIONS REQUIRE TEFLON SEALING TAPE OR PIPE DOPE F...

Page 4: ...lent is used BOILER PIPING 1 Plumb the circulator or zone valve on the BOILER SUPPLY line If using a separate circulator the pump flange can be mounted directly to the threaded pipe marked BOILER SUPP...

Page 5: ...5 PIPING USING SEPARATE CIRCULATOR PUMP RECOMMENDED PIPING USING ZONE VALVE WITH EXISTING HEATING SYSTEM CIRCULATOR...

Page 6: ...e on the boiler supply line 2 Pipe the BOILER RETURN connection to the boiler return line Be sure the return line is NOT plumbed to the suction side of any heating circulators This may require moving...

Page 7: ...7 PIPING USING SEPARATE CIRCULATOR PUMP RECOMMENDED PIPING USING ZONE VALVE WITH EXISTING HEATING SYSTEM CIRCULATOR...

Page 8: ...are factory installed 2 Pipe the BOILER RETURN connection to the boiler return line Be sure the return line is NOT plumbed to the suction side of any heating circulators This may require moving the he...

Page 9: ...9 PIPING MODELS WITH PRE INSTALLED CIRCULATOR W INTEGRAL FLOW CHECK...

Page 10: ...nted directly to the threaded pipe marked BOILER SUPPLY Alternately the circulator can be placed anywhere on the boiler supply line 2 Pipe the BOILER RETURN connection to the boiler return line Be sur...

Page 11: ...11 PIPING USING SEPARATE CIRCULATOR PUMP RECOMMENDED PIPING USING ZONE VALVE WITH EXISTING HEATING SYSTEM CIRCULATOR...

Page 12: ...the zone valve sensor contains a built in temperature offset to account for the time it takes the zone valve to fully close This results in potable water temperature that is representative of the Smar...

Page 13: ...BOX PLACE A WIRE NUT OVER EACH WIRE NOT USED ORANGE ORANGE BLUE BLUE VIOLET VIOLET WHITE BLACK HONEYWELL L8124 B D BOILERMATE CIRCULATOR L1 L2 L8124 B D B1 B2 C1 C2 2 1 B R B R W T T HIGH LIMIT LOW L...

Page 14: ...MIT HONEYWELL L8148 J WITH 24 VOLT GAS VALVE BOILERMATE JUNCTION BOX PLACE A WIRE NUT OVER EACH WIRE NOT USED ORANGE ORANGE BLUE BLUE VIOLET VIOLET WHITE BLACK BOILERMATE CIRCULATOR L1 L2 L8148J C1 C2...

Page 15: ...A C 2 1 ZC ZR B2 B1 C2 C1 T T BOILERMATE CIRCULATOR PRIORITY WIRING HONEYWELL L8124 A C L1 L2 BOILERMATE JUNCTION BOX ORANGE ORANGE BLUE BLUE VIOLET VIOLET WHITE BLACK HEATING CIRCULATOR PRIORITY WIR...

Page 16: ...ORITY WIRING HONEYWELL L8148B B R HIGH LIMIT BOILERMATE CIRCULATOR BOILERMATE JUNCTION BOX ORANGE ORANGE BLUE BLUE VIOLET VIOLET WHITE BLACK L1 L2 L2 L1 T T C1 C2 B1 B2 L8148B PRIORITY WIRING HONEYWEL...

Page 17: ...S VALVE BOILERMATE CIRCULATOR BOILERMATE JUNCTION BOX PLACE A WIRE NUT OVER EACH WIRE NOT USED ORANGE ORANGE BLUE BLUE VIOLET VIOLET WHITE BLACK TV W T TP Z B B1 B2 B3 L1 L2 C1 C2 8J48A HEATING CIRCUL...

Page 18: ...OLET VIOLET BLACK WHITE L1 L2 120V Supply BoilerMate Circulator PLACE A WIRE NUT OVER EACH WIRE NOT USED Typical Multi Zone Relay 24V without Post Purge Feature T T X X Boiler Aquastat Zone Outputs Pr...

Page 19: ...must be placed on a flat section of floor in an area where water will first collect If the level cannot reach 1 32 the alarm feature may not function Do not place in a high traffic area where the sens...

Page 20: ...trol 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 pow...

Page 21: ...oiler Aquastat Zone Outputs Priority or DHW Zone Thermostat Inputs Typical Multi Zone Relay BoilerMate Circulator BoilerMate Thermostat PRIORITY W CIRCULATORS SCHEMATIC 4 ZONE VALVES SCHEMATIC 3 3 WIR...

Page 22: ...R 4 WIRE ZONE VALVE L1 L2 40VA 24 VOLT L1 L2 NOTE TAKE L1 AND L2 OFF THE BOILER CONTROL T T ON BOILER CONTROL END SWITCH MOTOR ORANGE 1 ORANGE BLUE BLUE VIOLET VIOLET BLACK WHITE SMART CONTROL JUNCTIO...

Page 23: ...Support at 401 535 1216 Always disconnect power before wiring the unit Ensure that the proper conduit and connections are used per your local code In lieu of local code the National Electric Code sho...

Page 24: ...X LIVE NEUT PR OUT PR IN 1 2 3 4 L1 L2 Indirect Aquastat L1 L2 B2 B HONEYWELL L8148J W MILLIVOLT GAS VALVE WHITE RODGERS 8J48A W 24V GAS VALVE CIRCULATOR RELAY BOX Indirect Aquastat L2 LIVE NEUT PR OU...

Page 25: ...ar as hot water is used 3 START HEATER Turn power on to the unit Smart Control models come pre set at 120 F for safety Dial units should have the knob rotated to the 120 F mark The circulator and boil...

Page 26: ...until n is displayed Pressing the MODE pushbutton a fifth time will cause to be displayed and releasing the MODE pushbutton will cause 41 to be displayed This is the tank volume in gallons To change t...

Page 27: ...at exchanger as outlined below Install water treatment equipment to prevent recurrence 5 Check for undersized or faulty circulator stuck or undersized zone valve Ensure all shutoff valves are open Che...

Page 28: ...tom Drain O Ring 2500 178 2500 178 2500 178 2500 178 N A N A N A N A Smart Control 2704A233 2704A233 2704A233 2704A233 2704A233 2704A233 N A N A Sensor thermistor wire 2704 259 2704 259 2704 259 2704...

Page 29: ...phosphoric acid solution commercial icemaking cleaning solution into the water tank through the top opening Be sure that the manufacturer s directions and warnings are followed 29 15 CLEANING THE BOI...

Page 30: ...en to prevent pressure build up Electrocution hazard The BoilerMate must be electrically grounded Electrical supply must come from the boiler side of boiler s emergency shut off switch in order to pre...

Page 31: ...31...

Page 32: ...West Warwick Rhode Island 02893 Part 9040 586 07 08 Boiler Mate AMTROL AMTROL logo Therm X Trol Radiant EXTROL and EXTROL are registered trademarks of AMTROL Inc and affiliates All rights reserved...

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