Amtrol HM-80Z, HM-41Z, HM-80L, HM-41L warranty Startup Procedure, Troubleshooting

8. Startup Procedure

1.PURGE HEAT EXCHANGER: The heat exchanger should be free of large air pockets to allow the circulator to operate properly. Using the diagram below as a guide, isolate the boiler return line and flush the loop until large air pockets are purged. After this, the air elimination equipment will collect smaller air bubbles.

2.FILL TANK: Open the hot water fixture furthest from the heater. Open the cold water supply and allow the water to run until air stops emerging. Air pockets may appear at any hot water fixture. This is considered normal and will clear as hot water is used.

3.START HEATER: Turn power on to the unit. Digital Control models come pre-set to 120°F for safety. Mechanical controls should have the knob rotated to the 120°F mark. The circulator or zone valve should operate and the boiler should start.

4.CHECK OPERATION: The water heater will begin to heat. Depending upon the size of the water heater, output of the boiler and the space heating load, the unit should typically reach set temperature within 15 to 60 minutes. If heating does not occur, consult the troubleshooting section in this manual. Note: Large heaters coupled with small boilers may exceed this time period upon initial startup.

5.SET TEMPERATURE: The control should be set to the minimum temperature consistent with the user’s needs. This maximizes efficiency and reduces scald potential.

6.The water heater and system should be periodically checked by a licensed professional at least annually and more often as system ages.

1. Close
Return	3.
2. Fill	Purge
	Air
Boiler

9. Troubleshooting

PROBLEM	POSSIBLE CAUSES		SOLUTION
	1.	No power to unit	1.	Check circuit breaker, boiler emergency switch and boiler reset switch.
	2.	Circulator air-bound	2.	Purge air. Ensure circulator is on Boiler Supply. Check air vents.
No hot water	3. Faulty circulator or zone valve		3.	Check circulator and zone valve. Repair or replace if necessary.
	4.	Faulty control	4.	Check continuity. Switching circuits should close. If not, replace control.
	5.	Boiler inoperable	5.	Check boiler system. Boiler must operate to generate hot water.
	1.	Demand exceeds capacity	1.	Check sizing based on household size and boiler output.
	2.	Temperature too low	2.	Increase temperature setpoint.
	3.	Boiler lacks output for simultaneous heat & hot water	3.	Set up for priority. If problem persists add storage or increase tank size.
	4.	Fouled heat exchanger	4.	Check Boiler Supply/Boiler Return during cold startup. If difference is less
Insufficient hot water				than 20°F, clean heat exchanger as outlined below. Install water treatment
				equipment to prevent recurrence.
	5.	Insufficient heat exchanger flow	5.	Check for undersized or faulty circulator, stuck or undersized zone valve.
				Ensure all shutoff valves are open. Check for stuck flow check valve. Purge
				boiler loop to remove air.
	1.	Improper plumbing	1.	If Boiler Return is plumbed to the suction-side of a heating circulator, over-
				heating will occur when the home’s heat is on. Fix plumbing.
Water too hot	2.	Temperature set too high	2.	Reduce temperature setting.
	3.	Temperature sensor not fully inserted	3.	Re-insert temperature sensor.
	4.	Stuck zone valve	4.	Repair or replace.
	5.	Flow check valve stuck open	5.	Clean, repair or replace.
	1.	Thermal expansion tank undersized or missing	1.	Install the properly sized thermal expansion tank.
Relief valve dripping	2.	Thermal expansion tank set improperly	2.	Ensure precharge air pressure matches static water pressure.
	3.	City pressure too high	3.	Install a Pressure Reducing Valve (PRV) if city pressure is over 80psi.
or opening
	4.	System over temperature	4.	Determine cause of over temperature condition and correct problem.
	5.	Faulty relief valve	5.	Replace relief valve.
Discolored water	1. Poor water quality		1.	Have water tested for contaminants.
at faucet	2. Sediment or suspended particles		2.	Install sediment filter, purge unit more often to avoid future problems.
	1.	Improper or loose wiring	1.	Check connections against wiring diagrams in this manual.
Boiler will not operate	2.	Boiler high limit has been reached	2.	Boiler will periodically cycle on and off during operation.
	3. Post Purge (POS) set too high		3.	Post Purge shuts the boiler off prior to reaching domestic setpoint. If set too
when calling for	4.	Problem with boiler system		high, the boiler may not have enough energy to raise the water temperature
hot water
				to setpoint. Reduce POS or set to 0 if the problem persists.
			5.	Have boiler diagnosed for proper operation.

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