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1. TABLE OF CONTENTS
2. Pre-Installation Checklist ..............................2
3. Required Components and
Accessories Checklist ...................................3
4. CH-41Z/CH80Z Piping Installation ...............4
5. CH-41BZ Piping Installation ..........................6
6. Wiring ............................................................8
7. Startup Procedure For All Models ..............10
8. Troubleshooting ..........................................11
9. Replacement Parts ......................................12
10. General Safety Information ........................13
2. PRE-INSTALLATION CHECKLIST
IMPORTANT STEPS AND DECISIONS REQUIRED BEFORE INSTALLATION
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THIS PRODUCT MUST BE INSTALLED AND
MAINTAINED BY A LICENSED PROFESSIONAL. IN
ADDITION TO THE INSTRUCTIONS IN THIS MANUAL,
FOLLOW ALL APPLICABLE LOCAL AND STATE CODES
OR IN THE ABSENCE OF SUCH CODES, THE CURRENT
EDITIONS OF THE NATIONAL PLUMBING CODE AND
THE NATIONAL ELECTRIC CODE.
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DRIP PAN AND DRAIN: This appliance should not
be installed in an area where leakage of the tank or
connections can result in damage to the area adjacent
to the appliance or to lower floors of the structure.
When such locations cannot be avoided, a suitable
drain pan, adequately drained and kept clear, must be
installed under the appliance.
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CAUTION: Determine whether your water is corrosive
or acidic, and that there are no suspended solids,
toxic or other substances or abnormally high chlorine
levels in the water that could damage or affect the
BOILERMATE
®
or the rest of your plumbing system.
USE
GLYCOL
ONLY
WITH
DOUBLE-WALLED HEAT EXCHANGER
MODELS. Glycol is a hazardous substance. To avoid
seepage or leakage of glycol to surfaces where
humans or animals can ingest it, use glycol only in
double-walled units, so that any leaks will most likely
be released to the atmosphere. However, a leak to a
surface area may still occur, so any use of glycol must
be monitored closely and humans and animals should
be protected from contact with the unit.
Do not connect the BoilerMate
®
domestic supply with baseboard
or other space heating units or elements. Any
contaminants in the baseboard units will contaminate
the potable water in the BoilerMate
®
and also adversely
affect its performance.
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Select Circulator versus Zone Valve
The flow of hot boiler water to the BoilerMate
®
can
be controlled with either a motorized zone valve or a
circulator.
1. Separate circulator. The recommended way to
provide adequate flow through the BoilerMate
®
heat
exchanger is to use a separate dedicated circulator
with a minimum flow rate of 4 gpm. This option may
be used even though the heating system utilizes zone
valves.
2. Zone valve (system flow of 4-8 gpm). If a zone valve
is to be used, a minimum flow rate of 4 gpm with all
zones in use is required. A full-port zone valve should
be used.
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All installations require a low-water cut-off or automatic fill
valve on your boiler system to reduce the risk of boiler water
loss.
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In steam boiler installations a low-water cut-off which is also
required by most codes.
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Installation of a vacuum breaker is required to prevent
damage to the BoilerMate
®
when drained. There must
be no valves installed between the vacuum breaker and
BoilerMate
®
.
