Amtrol EXTROL AX SERIES Installation instructions

EXTROL® AX SERIES
PRESSURIZED EXPANSION TANKS (ASME)
INSTALLATION & OPERATION INSTRUCTIONS
Models AX-15(V)-(DD) through AX-280(V)-(DD)
READ CAREFULLY THE PRODUCT
INSTALLATION & OPERATION INSTRUCTIONS.
FAILURE TO FOLLOW THE INSTRUCTIONS AND WARNINGS IN
THE MANUAL MAY RESULT IN SERIOUS OR FATAL INJURY AND/
OR PROPERTY DAMAGE, AND WILL VOID THE PRODUCT
WARRANTY. THIS PRODUCT MUST BE INSTALLED BY A LICENSED
PROFESSIONAL. FOLLOW ALL APPLICABLE LOCAL AND STATE
CODES AND REGULATIONS, IN THE ABSENCE OF SUCH CODES,
FOLLOW THE CURRENT EDITIONS OF THE NATIONAL PLUMBING
CODE AND NATIONAL ELECTRIC CODE, AS APPLICABLE.
EXPLOSION OR RUPTURE HAZARD. THE
EXPANSION TANK MUST BE OPERATED SO
THAT THE PRESSURE DOES NOT EXCEED THE MAXIMUM
WORKING PRESSURE.
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 240° F.
Do not adjust the pre-charge or re-pressurize this Product except for any
adjustments required at the time of initial installation, especially if
Product is corroded, damaged or with diminished integrity. Adjustments
to pre-charge must be done at ambient temperature only. Failure to
properly size the Product or follow these instructions may result in
excessive strain on the system lead to Product failure, serious or fatal
personal injury, leakage and/or property damage.
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 a Therm-X-Trol®for potable water systems and a
Radiant Extrol®for radiant heating systems. Do not install on dead-
end pipe.
This product can expose you to chemicals
including lead, which is known to the State of
California to cause cancer and birth defects or other reproductive harm.
For more information go to www.P65Warnings.ca.gov.
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.
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 RISK OF PERSONAL INJURY AS WELL AS
PROPERTY DAMAGE.

EXPLOSION HAZARD. Failure to follow
instructions in the accompanying product manual
can cause rupture or explosion, possibly causing serious or fatal injury,
leaking or flooding and/or property damage.
FAILURE TO PROPERLY SEAL VALVE CAP
WILL RESULT IN LOSS OF PRECHARGE
CAUSING PRODUCT TO FAIL.
Location of EXTROL®Expansion Tanks
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.
AX-15(DD) through AX-280(DD) models are not
designed to be hung from the piping. If the tank is
to be suspended from the piping, the tank and the piping needs to be
properly supported in order to hold the wet weight of the tank.
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
LICENSED 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.
IMPORTANT: If increasing pre-charge pressure above
55 psig the following steps must be followed:
a. Tank must be connected to the system with the isolation
valve open.
b. System must be pressurized to 13-14 psig, slightly above
factory setting.
c. Isolation valve needs to be shut.
d. Pre-charge pressure of tank can now be increased to match
system fill pressure.
e. Open isolation valve and start up system.
Failure to follow these steps could result in damage to the
bladder and void all warranties.
5. After making sure the air charge is correct, replace the valve cap and
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
[phone].
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 lock-shield valve in tank-to-system piping.
c. Open drain valve to empty 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.
PLEASE READ THE FOLLOWING INSTRUCTIONS CAREFULLY
IMPORTANT GENERAL SAFETY INFORMATION -
ADDITIONAL SPECIFIC SAFETY ALERTS APPEAR IN THE FOLLOWING INSTRUCTIONS.
Warranty
AX Series Models: One (1) Year Limited Warranty
Visit www.amtrol.com for complete warranty details.
Firing Rate of
Boiler Length of Pipe Connecting Tank to System:
MBTU/H Below 11' 11' – 30' 31' – 100'
2,000 1/2"3/4" 1"
4,000 3/4" 1" 11/4"
8,000 1" 11/4" 11/2"
12,000 11/4" 1 1/2" 2"
16,000 11/4" 2" 21/2"
20,000 11/2" 2" 21/2"

AMTROL
AIR ELIMINATOR
DRAIN
PUMP
TRI-FLOW
VALVE
SUPPLY
SUCTION
DIFFUSER
RETURN
ISOLATION VALVE
DRAIN
AMTROL
AUTOMATIC
FILL VALVE
C.W.S.
AMTROL
AIR ELIMINATOR
AMTROL
AIR SEPARATOR
DRAIN
PUMP
TRI-FLOW
VALVE
SUPPLY
SUCTION
DIFFUSER
RETURN
ISOLATION VALVE
AMTROL
AUTOMATIC
FILL VALVE
DRAIN
C.W.S.
AMTROL
EXTROL
TANK
AMTROL
EXTROL
TANK
AMTROL
EXTROL®
TANK
AMTROL
AIR SEPARATOR
ALTERNATE AIR SEPARATOR LOCATION
RETURN
HIGH POINT IN SYSTEM
POINT OF LOWEST SOLUBILITY
Suggested Piping Diagram
Alternate Piping Diagrams
AMTROL
AIR ELIMINATOR
DRAIN
PUMP
TRI-FLOW
VALVE
SUPPLY
SUCTION
DIFFUSER
RETURN
ISOLATION VALVE
DRAIN
AMTROL
AUTOMATIC
FILL VALVE
C.W.S.
AMTROL
AIR ELIMINATOR
AMTROL
AIR SEPARATOR
DRAIN
PUMP
TRI-FLOW
VALVE
SUPPLY
SUCTION
DIFFUSER
RETURN
ISOLATION VALVE
AMTROL
AUTOMATIC
FILL VALVE
DRAIN
C.W.S.
AMTROL
EXTROL
TANK
AMTROL
EXTROL
TANK
AMTROL
EXTROL®
TANK
AMTROL
AIR SEPARATOR
ALTERNATE AIR SEPARATOR LOCATION
RETURN
HIGH POINT IN SYSTEM
POINT OF LOWEST SOLUBILITY

© 2019 Worthington Industries Inc. Part #: 9017-093 (01/19)
One or more features of this product are covered by U.S. patents, visit www.amtrol.com/patents for more information.
1400 Division Road, West Warwick, RI USA 02893
T: 800.426.8765 www.amtrol.com