Amtrol EXTROL EX Series

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USE ONLY IN RESIDENTIAL CLOSED

HYDRONIC SYSTEMS. Do not install on domestic

water systems, or in open heating systems. Corrosion and tank failure

may result. Use a Therm-X-Trol

or Therm-X-Span

for domestic water

systems. Use a Radiant EXTROL

for radiant heating systems where air

elimination equipment or barrier tubing is not used.

READ CAREFULLY THE PRODUCT

INSTALLATION, OPERATING AND

MAINTENANCE MANUAL. 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.

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.

RUPTURE OR EXPLOSION HAZARD. Do not

expose product to freezing temperatures or

temperatures in excess of 240°F. Do not adjust the pre-charge or

re-charge this Product except during installation or regular inspection.

Replace the Product and do not adjust the pre-charge if 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

and may lead to Product failure, serious or fatal personal injury, leakage,

and/or property damage.

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

professional should inspect the 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

PRESSURE BUILD-UP WHICH CAN RESULT IN PRODUCT FAILURE,

SERIOUS INJURY OR DEATH AND/OR SEVERE PROPERTY

DAMAGE AND VOID THE PRODUCT WARRANTY.

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.

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.

EXTROL

EXPANSION TANKS FOR HYDRONIC HEATING & CHILLED WATER SYSTEMS

INSTALLATION & OPERATION INSTRUCTIONS

NOTE: Inspect for shipping damage. 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.

Models EX-15 through EX-90

Models SX-30V through SX-160V

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Summary

General Safety and Hazard Warnings

Safety Alert Symbol Usage

Explains the purpose of the safety alert symbol to warn of potential hazards.

Residential Hydronic System Restrictions

Mandates use only in residential closed hydronic systems, not domestic water systems.

Manual Compliance and Professional Installation

Emphasizes following manual instructions and professional installation by a licensed professional.

Product Pressure and Rupture Hazards

Warns that pressurized products can weaken, burst, or explode, causing injury or damage.

Rupture or Explosion Hazard Details

Specifies hazards related to freezing temperatures or exceeding 240°F, and pre-charge adjustments.

Relief Valve Installation and Inspection

Requires relief valve installation and inspection every 3 years or if discharge is present.

Water Quality Impact on Product Life

Advises testing water for corrosive elements and treating it for satisfactory performance.

Chemical Exposure Warning (California Prop 65)

Informs about potential exposure to chemicals, including lead, known to cause cancer or reproductive harm.

Pre-Installation Procedures

Damage Inspection and Sizing

Inspect for shipping damage and ensure the expansion tank is sized properly for the application.

Precharge Pressure Adjustment

Adjust the precharge pressure of the tank to match the system fill pressure.

Installation Guidelines

System Preparation and Tank Placement

Drain the system or isolate the area and install the EXTROL on the suction side of the circulator.

System Pressurization and Leak Verification

Pressurize the system, check for leaks, and verify relief valve discharge.

Maintenance and Service

Periodic System and Tank Inspection

Professionally check the system and expansion tank yearly, paying attention to precharge and indicator cap.

InSight Service Indicator Cap

Monitor the InSight™ service indicator cap for discoloration, indicating potential tank failure.

Product Warranty Information

Limited Warranty Terms

Details the five (7) year limited warranty for EX models and one (1) year for SX models.

Summary

General Safety and Hazard Warnings

Safety Alert Symbol Usage

Explains the purpose of the safety alert symbol to warn of potential hazards.

Residential Hydronic System Restrictions

Mandates use only in residential closed hydronic systems, not domestic water systems.

Manual Compliance and Professional Installation

Emphasizes following manual instructions and professional installation by a licensed professional.

Product Pressure and Rupture Hazards

Warns that pressurized products can weaken, burst, or explode, causing injury or damage.

Rupture or Explosion Hazard Details

Specifies hazards related to freezing temperatures or exceeding 240°F, and pre-charge adjustments.

Relief Valve Installation and Inspection

Requires relief valve installation and inspection every 3 years or if discharge is present.

Water Quality Impact on Product Life

Advises testing water for corrosive elements and treating it for satisfactory performance.

Chemical Exposure Warning (California Prop 65)

Informs about potential exposure to chemicals, including lead, known to cause cancer or reproductive harm.

Pre-Installation Procedures

Damage Inspection and Sizing

Inspect for shipping damage and ensure the expansion tank is sized properly for the application.

Precharge Pressure Adjustment

Adjust the precharge pressure of the tank to match the system fill pressure.

Installation Guidelines

System Preparation and Tank Placement

Drain the system or isolate the area and install the EXTROL on the suction side of the circulator.

System Pressurization and Leak Verification

Pressurize the system, check for leaks, and verify relief valve discharge.

Maintenance and Service

Periodic System and Tank Inspection

Professionally check the system and expansion tank yearly, paying attention to precharge and indicator cap.

InSight Service Indicator Cap

Monitor the InSight™ service indicator cap for discoloration, indicating potential tank failure.

Product Warranty Information

Limited Warranty Terms

Details the five (7) year limited warranty for EX models and one (1) year for SX models.

This document provides installation and operation instructions for Extrol Expansion Tanks, specifically models EX-15 through EX-90 and SX-30V through SX-160V, designed for hydronic heating and chilled water systems.

Function Description

Extrol expansion tanks are designed to manage the expansion and contraction of water in closed hydronic heating and chilled water systems. As water heats up, it expands, increasing pressure within the system. The expansion tank provides a space for this expanded water, preventing excessive pressure buildup and protecting system components. Conversely, as water cools and contracts, the tank helps maintain system pressure. The tanks are pre-charged with air, which acts as a cushion, separating the system water from the air chamber via a diaphragm.

Important Technical Specifications

The manual provides a sizing chart (Figure 1) based on boiler net output in 1000s of BTU/Hr and various types of radiation (Finned Tube Baseboard or Radiant Panel, Convectors or Unit Heaters, Cast Iron Radiators, Cast Iron Baseboard). This chart helps in selecting the appropriate Extrol model (EX or SX series) for a given system. For example, a boiler with 100,000 BTU/Hr output using finned tube baseboard would typically require an EX-30 model, while a 500,000 BTU/Hr output with cast iron baseboard would require an SX-90V. The sizing is based on a 12 psig fill pressure, 30 psig relief valve, and 200°F average temperature.

The tanks are designed to operate within specific temperature limits: they should not be exposed to freezing temperatures or temperatures exceeding 240°F.

Usage Features

Pre-Installation:
- Visually inspect for shipping damage.
- Ensure proper sizing according to Figure 1.
- Remove the plastic cap from the air stem (Figure 2) with the tank empty of water.
- Check and adjust the pre-charge pressure to match the boiler fill valve setting.
- Replace and snugly tighten the cap, ensuring it is flush with the tank surface.
- Safety Warning: Failure to properly seal the cap will result in loss of precharge, causing product failure.
Installation:
- Drain the boiler system or isolate the installation area.
- Install the Extrol on the supply side of the boiler, on the suction-side of the heating circulator(s) (Figure 3).
- Pressurize the system and check for leaks.
- Restart the boiler system and check for relief valve discharge. If the relief valve drips, the tank may be improperly charged or undersized.
- Mounting: In-line models (EX-15 through EX-90) can be mounted vertically in a downward position. Ensure piping can support the full weight of the tank when full of water. Stand models (SX-30V through SX-160V) are floor standing and should not be hung from the piping.
- Placement: Do not install the Extrol on a dead-end pipe or wherever air can collect, as this can cause corrosion and possible leakage.
System Compatibility: Designed for use only in residential closed hydronic systems. Not suitable for domestic water systems or open heating systems, as this can lead to corrosion and tank failure. For domestic water systems, Therm-X-Trol® or Therm-X-Span® should be used. For radiant heating systems without air elimination or barrier tubing, a Radiant EXTROL® is recommended.

Maintenance Features

Regular Inspection: A professional plumber should check the complete system, including the expansion tank, yearly and more frequently as the system ages.
Pre-charge Check: The pre-charge should always be checked with the tank isolated and empty of water. Maintaining the proper pre-charge is crucial. A small quantity of air may escape over time, leading to insufficient air charge.
InSight™ Service Indicator Cap (Inline models only): Monitor the tip of the inspection cap for discoloration (Figure 4).
- Normal Operation: Clear/White cap.
- Water Present: Discolored cap, indicating water in the air chamber, which suggests the diaphragm has failed.
- Replace Tank: If the cap is discolored, tank replacement is required. However, do not rely solely on the cap as the only indicator of tank condition.
Relief Valve Inspection: A relief valve must be installed to prevent pressure exceeding local code requirements or the product's maximum working pressure. At least once every 3 years, or if discharge is present, a licensed professional should inspect the pressure relief valve and replace it if corrosion is evident or the valve does not function. Failure to inspect this valve can lead to unsafe pressure buildup, product failure, serious injury or death, severe property damage, and will void the product warranty.
Water Quality: Water quality significantly influences the life of the product. Test for corrosive elements, acidity, total solids, and other contaminants, including chlorine, and treat water appropriately to prevent premature failure.

Safety Warnings

The manual emphasizes several critical safety warnings:

General Safety: This is a safety alert symbol. Obey all safety messages to reduce the risk of personal injury and property damage.
Professional Installation: The product must be installed by a licensed professional, following all applicable local and state codes and regulations.
Product Integrity: Like most products under pressure, this product may corrode, weaken, burst, or explode over time, causing serious injury, leakage, or property damage. Periodic inspection and service by a licensed professional are essential.
Leakage Prevention: A drip pan connected to an adequate drain must be installed if leaking or flooding could cause property damage. Do not locate the product in areas where leakage could damage adjacent areas or lower floors.
Rupture/Explosion Hazard: Do not expose the product to freezing temperatures or temperatures exceeding 240°F. Do not adjust the pre-charge or re-charge the product except during installation or regular inspection. Replace the product if corroded, damaged, or with diminished integrity. Adjustments to pre-charge must be done at ambient temperature only.
Chemical Exposure: 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. More information is available at www.P65Warnings.ca.gov.