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1. TABLE OF CONTENTS
2. Pre-Installation Checklist .................................................
2
3. Required Components and Accessories Checklist .........
3
4. WH-7 & 9 Classic Series Piping Installation ....................
4
5. Top Down™ TD-Series Piping Installation ......................
6
6. Ready-To-Run RTR-Series Piping Installation ................
8
7. WHS Premier Series Piping Installation ........................
10
8. Wiring All Smart Control™ Models ...............................
12
9. Wiring All Dial Control Models (Except RTR Models) .........
20
10. Wiring All Ready-To-Run (RTR) Models .......................
23
11. Startup Procedure For All Models ................................
25
12. Setting the Smart Control™ ..........................................
26
13. Troubleshooting .............................................................
27
14. Replacement Parts ........................................................
28
15. Cleaning the BoilerMate
®
Heat Exchanger ...................
29
16. General Safety Information ...........................................
30
2. PRE-INSTALLATION CHECKLIST
IMPORTANT STEPS AND DECISIONS REQUIRED BEFORE INSTALLATION
M 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.
M 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.
M 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.
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 system (boiler and
distribution elements).
1. Non-Priority System - The controls of the
BOILERMATE
®
must be wired as a separate heating
zone with a standard zone valve or a separate
circulator dedicated to the BOILERMATE
®
“zone”.
NOTICE: In this non-priority option, the BOILERMATE
®
will be supplied just as another zone. This means that if all
space heating zones call for hot boiler water at the same
time, the BOILERMATE
®
may not be supplied with enough
hot boiler water to “recover” adequately. The delivery of
domestic hot water will be diminished. In many, but not all
cases, this is not a problem because the routine oversizing
of boiler output is adequate for both loads.
2. Priority System - Under this wiring option the
BOILERMATE
®
will be supplied before space heating.
In limited circumstances, space
heating can be lost in the home in
this priority mode. Any demand for space heating is
postponed until the BOILERMATE
®
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.
M 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 5 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 5 gpm with all
zones in use is required. A full-port zone valve should
be used.
M All installations require a low-water cut-off or automatic fill
valve on your boiler system to reduce the risk of boiler water
loss.
M Steam boiler installations require a low-water cut-off which
is also required by most codes.
M 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
BOILEMATE
®
.