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(OVER)
INSTALLATION
The FILL-TROL
®UNIT
Model 109 FILL-TROL
The FILL-TROL unit is a combination TANK (the unique, specially adapted, pressurized,
EXTROL®diaphragm-type expansion tank), and a specially designed automatic
pressure reducing valve. The FILL-TROL tank provides an air chamber to receive
the expanded volume of water, which is created in the heating system as the water is
heated. It is, therefore, essentially an expansion tank. Pressurizing the tank with a
12-psig air charge results in the pressure-reducing valve being set to 12 psig. Any
adjustment to the precharge automatically adjusts the pressure reducing valve setting.
It is air-charged at the factory to 12 psig and is ready to install in residential and most
commercial systems without adjustments when received.
The FILL-TROL valve fills the system with water and automatically shuts off the flow
when the system is filled and pressurized to 12 psig. It will also restore the system
pressure to 12 psig if the pressure falls below this point.
The FILL-TROL unit, therefore, will automatically take care of system water expansion
and automatically fill the system and maintain a minimum system pressure in a simple
manner to provide a more satisfactory heating system operation.
QUAD
CHECK
AIR
PURGER
AIR
VENT
SUPPLY
MAIN
COLD WATER
SUPPLY
RELIEF
VALVE
AUTOMATIC
FILL VALVE
BOILER
CIRCULATOR RETURN
MAIN
FILL-TROL
TANK
1/2" PIPE NIPPLE
FILL-TROL
VALVE
STANDARD
PIPE TEE
(OPTIONAL)
1/2" COMPRESSION
FITTING
CONNECTION
COLD WATER
SUPPLY
AMERICAN
AIR VENT
AND AIR PURGER
HEATING SYSTEM
SUPPLY MAIN
An ideal residential FILL-TROL installation is
to mount it on the bottom of an AMTROL
American air vent and purger, located on the
heating system supply main or it may be in
a standard pipe tee (see Figure 1).
To Install
1. Make connection to system with 1/2” pipe
nipple from tapping marked “SYSTEM”.
2. Connect 1/2” copper tubing cold water
supply to 1/2” compression fitting con-
nection at “SUPPLY”.
Form 109-1A
Supersedes Form 109-1
FIGURE 1
West Warwick, Rhode Island 02893
INSTALLATION & OPERATION
INSTRUCTIONS
For Use with FILL-TROL Combination
Expansion Tank and Valve Units
MC#2694
Part No. 9015-026 (11/02)
West Warwick, Rhode Island 02893
OPERATION
FIGURE 2
FIGURE 3
SERVICE HINTS
Printed in
U.S.A.
The FILL-TROL unit operates in the following manner:
Referring to Figure 2, water enters the FILL-TROL valve through
the 1/2” compression fitting connection, passes through the
strainer and pushes open the spring-loaded check valve. It then
flows through the automatic shut-off valve, which is held in the
open position by the charge pressure in the FILL-TROL tank
forcing the diaphragm against the pressure plate, which raises
the fillgate stem, compressing the automatic shut-off valve
spring. The water then flows through the valve body and through
the system connection to the heating system. As the system
reaches fill pressure of 12 PSI, the diaphragm in the FILL-TROL
tank depresses, permitting the automatic shut-off valve to close
(see Figure 3).
If the system falls below 12 PSI, the diaphragm again pushes
open the automatic shut-off valve, permitting water to flow into
the system to restore system pressure.
NOTE: Although FILL-TROL is shipped from the factory with a
standard 12 lb. air charge which automatically sets the
minimum fill pressure to 12 lbs., other minimum fill
pressures may be selected by simply increasing or
decreasing the air charge in the tank to the desired
minimum fill pressure. FILL-TROL must be empty
(free of water) when changing the air charge.
To place FILL-TROL unit into operation, proceed as follows:
A. Open water supply shut-off valve and allow system to fill.
B. After system is filled, the pressure should be 12 psig. After the
boiler is brought up to operating temperature, pressure gauge
will read higher than fill pressure. If the pressure is higher than
desired, draw water from system until desired gauge reading
is obtained. A good operating pressure is 18-20 psig. Do not
let air out of the FILL-TROL tank.
1. If a system is shut down for long periods or emptied, repeat
procedure described in Step B, above.
2. If, on reheat cycle, the system pressure is greater than 20 psig:
a. Check indicator on boiler gauge.
b. Close water supply shut-off and drain system pressure
below 12 psig. Open shut-off and allow system to fill. When
FILL-TROL valve stops feeding, boiler pressure gauge
should read 11-13 psig.
3. If pressure relief valve drips:
a. Check system pressure. If pressure is at relief pressure
setting, reduce by drawing off boiler water.
b. If drip continues at reduced pressure, flush relief valve seat
by quickly raising level several times. Inspect FILL-TROL
and tank-less heater for leakage if dripping continues.
4. To remove screen in FILL-TROL valve for cleaning, shut off
main water supply to heating system and remove compression
nut (See Figure 2, above).
5. To make repairs to heating system, simply close water supply
shut-off valve and drain system. After repairs have been
made, open valve for filling.

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