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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 

advised that 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.

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 water heater  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, 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 a diaphragm 

expansion tank and the boiler temperatures are being changed, resize the 

expansion tank.

If installing on city water supply, a properly sized 

thermal expansion tank is required with the water 

heater and should be installed as set fo rth in the 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 water heater 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 is 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 obtained at the place of purchase.  

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 water heater 

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 to the 

area adjacent to the appliance or to lower floors of the structure.

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 monitored for leakage.

CALIFORNIA PROPOSITION 65 WARNING!

 This 

product contains a chemical known by the State of 

California to cause cancer and to cause 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.htm

As in all plumbing products and water storage 

vessels, bacteria can grow in this Product, especially 

during times of non-use.  Consult your local plumbing professional 

regarding any steps you may wish to take to safely disinfect your home’s 

plumbing system.

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.  At least once every 3 years or if 

discharge is present, a licensed contractor should inspect the temperature 

and pressure relief valve and replace if corrosion is evident or the valve 

does not function.  

FAILURE TO INSPECT THIS VALVE AS DIRECTED 

COULD RESULT IN UNSAFE TEMPERATURE OR PRESSURE 

BUILD-UP WHICH CAN RESULT IN PRODUCT FAILURE, SERIOUS 

INJURY OR DEATH AND/OR SEVERE PROPERTY DAMAGE AND 

VOID THE PRODUCT WARRANTY.

10. General Safety Information

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Summary of Contents for HYDROMAX HM-41L

Page 1: ...IONAL 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...

Page 2: ...her zone This means that if all space heating zones call for hot boiler water at the same time the water heater may not be supplied with enough hot boiler water to recover adequately The delivery of d...

Page 3: ...er Inlet Retaining Screws 2 Heat Trap Boiler Supply Hot Water Outlet 15 10 5 0 0 2 4 6 8 Head Loss Feet Flow Gallons Per Minute HYDROMAX Components 2 Piece Cover Removal and Installation Heat Exchange...

Page 4: ...code Do not drill puncture or otherwise penetrate the steel outer tank shell Do not screw pipe hangers or other hardware into the exterior of the tank BOILER PIPING 1 Plumb the circulator or zone val...

Page 5: ...t wiring which is external to the water heater jacket when all panels are in place and which is part of the appliance shall be protected by metal conduit metal clad cable or raceways Power Limited Cir...

Page 6: ...GE WHITE BLACK BLUE BLUE VIOLET VIOLET POWER BURNER PUMP PRIORITY Multi Zone Control Using Post Purge L1 L2 TO BOILER X X BOILERMATE CIRCULATOR HEATING CIRCULATOR ORANGE ORANGE WHITE BLACK BLUE BLUE V...

Page 7: ...n Leak in sensor well Slow Heating Unit has taken over 60 minutes to reach hot water setpoint or cannot reach setpoint Faulty equipment Fouled heat exchanger No fuel Water Alarm Standing water detecte...

Page 8: ...TRANSFORMER L1 L2 4 Wire AQUASTAT Boiler Control Input HYDROMAX CIRCULATOR OR ZONE VALVE DHW ZONE AQUASTAT HYDROMAX CIRCULATOR COIL 2 3 1 4 6 5 HONEYWELL R4222D 1013 OR EQUIVALENT DPDT RELAY T C1 L2...

Page 9: ...faucet 1 Poor water quality 2 Sediment or suspended particles 1 Have water tested for contaminants 2 Install sediment filter purge unit more often to avoid future problems Boiler will not operate when...

Page 10: ...obtained at the place of purchase 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...

Page 11: ...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...

Page 12: ...ET 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 1400 Division Road West Warwick RI 02893 T 401 884 630...

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