Amtrol Essential Safety and Installation Guidelines for LBC 35 and LBC 85 Models

PLEASE READ THE FOLLOWING INSTRUCTIONS CAREFULLY

POTABLE WATER AND RADIANT HEATING WARNING. THIS PRODUCT MUST NOT BE USED IN RADIANT HEATING, POTABLE WATER OR OPEN SYSTEMS OF ANY KIND. THESE SYSTEMS CONTAIN OXYGENATED WATER WHICH WILL

CAUSE INTERNAL CORROSION AND PREMATURE PRODUCT FAILURE. USE

ATHERM-X-TROL®FOR POTABLE WATER SYSTEMS AND A RADIANT EXTROL™ FOR RADIANT HEATING SYSTEMS. MOUNT VERTICALLY ONLY. DO NOT INSTALL ON DEAD-END PIPE.

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 VIEWED AT WWW.AMTROL.COM. USE PROPER SAFETY EQUIPMENT WHEN INSTALLING.

FAILURE TO PROPERLY SEAL WILL RESULT IN LOSS

OF PRECHARGE CAUSING PRODUCT TO FAIL. GENERAL SAFETY INFORMATION - ADDITIONAL SPECIFIC SAFETY ALERTS APPEAR IN THE FOLLOWING INSTRUCTIONS.

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.

Location of EXTROL® Expansion Tanks

DO NOT LOCATE THIS PRODUCT WHERE LEAKING

OR FLOODING COULD CAUSE DAMAGE TO THE

SURROUNDING PROPERTY.

The AMTROL® expansion tank may be placed in any convenient position within the mechanical room (or building). If multiple tanks are installed, they should all be on the same level.

Point of Connection

Unlike a conventional tank, the EXTROL® sealed air cushion does not require replenishment so DO NOT connect to an air separator or other air collection device.

As with any expansion tank, it is recommended that the EXTROL® be connected to the suction side of the pump. This will prevent the pump head from becoming subtractive which may result in entry of air and vapor formation at high points in the system.

By connecting the EXTROL® on the boiler return, displacement of coolest system water into tank is ensured reducing energy waste.

Low pressure drop components such as air separators and boilers may be placed between point of connection and pump suction if desired. System design will dictate the feasibility of this.

Natural convection losses and the entry of air into tanks are eliminated by connection to the side or underside of main pipe. The piping should be pitched up and away from the EXTROL® to eliminate any potential air traps.

Installation

THIS PRODUCT MUST BE INSTALLED BY A QUALIFIED

PROFESSIONAL.

1.Note location of system connection, air charge valve and drain connection on tank.

2.Remove the plug or pipe cap from the system connection.

3.Remove the 1 1/2” NPT plug covering the air charge valve.

4.Before making any connection to the tank, check the tank and air charge (use an accurate pressure gauge). The air pressure must be equal to the minimum system pressure at the tank location.

5.After making sure the air charge is correct, replace the 1 1/2” plug over the air valve.

6.The EXTROL® may now be piped to the system (use the suggested EXTROL® piping diagrams on the next page).

7.Using the table below, select appropriate pipe size. Connection to each EXTROL® must have a lock shield gate valve and union to allow isolation and removal if required. Make up and fill valves, whether manual or automatic, should be tied into the connecting line. This will ensure that pump operation will not affect valve operation.

Operational Limits

Maximum Operating Pressure: As stamped on nameplate

Maximum Operating Temperature: 240 °F

Minimum Operating Temperature: 35°F (non-glycol application)

If unit is being installed in a glycol system where minimum temperatures fall below 35°F, contact the AMTROL technical service department at (401) 535-1216.

Operating Instructions

1.Check the expansion tank pre-charge before the system is filled with water. The charge is 12 psig unless noted otherwise on the tank label. Check to make sure this is the correct pre-charge pressure specified for the system.

2.If the tank pre-charge pressure needs to be changed on a dry system follow the following procedure:

a.Check the expansion tank air pressures at the pre-charge connection with an accurate tire type pressure gauge. The pre-charge connection is the same kind of connection found on automobile tires.

b.If the pressure is low, charge the tank with nitrogen gas or with oil free compressed air. Check the pressure frequently during this process as you would when filling a tire with air.

DANGER: Excessive pressure can cause tank to explode. Exercise care when filling a tank with air so the pressure does not exceed that required or does not exceed the working pressure of the tank as stamped on the nameplate. Failure to follow these instructions will result in serious

personal injury or death and property damage.

3.If, after the system has been filled with water and operating, it is found that the expansion tank pre-charge must be changed use the following procedure:

a.Turn off the heat source and allow the system water to cool to ambient temperature.

IMPORTANT: Expansion tank cannot be properly air charged other than at ambient temperature.

b. Close the lock-shield valve in the tank-to-system piping. c. Open the drain valve to empty the water from the tank. d. Check the tank air pressure at the pre-charge connection

with an accurate tire type air gauge. e. Refer to 2b above.

f.Close the drain valve, open the lock-shield valve and turn on the heat source.

g.Relock the lock-shield valve.

Firing Rate		Length of Pipe Connecting
of Boiler		Tank to System:
MBTU/H	Below 11’	11’ – 30’	31’ – 100’
2,000	1/2”	3/4”	1”
4,000	3/4”	1”	1 1/4”
8,000	1”	1 1/4”	1 1/2”
12,000	1 1/4”	1 1/2”	2”
16,000	1 1/4”	2”	2 1/2”
20,000	1 1/2”	2”	2 1/2”