Aerco AM 1000B Page 134 User Manual Download

Page: 134 / 154

AM Series Boilers and Water Heaters

CHAPTER 10 – MAINTENANCE

Page

134

154

AERCO International, Inc.

•

100 Oritani Dr.

•

Blauvelt, NY 10913

OMM-0100_0D

03/28/16

Ph.: 800-526-0288

GF-146

10.27 Maintenance Kits Part Lists

The annual and 24-month maintenance kits for the various models of AM units are shown in the
table below. The basic kit part number is

58109

, with the suffix of

-01

through

-06

appended to it

to indicate the specific kit required.

AM Series Maintenance Kit (P/N 58109) P/N Suffix and Part List

P/N

SUFFIX

DESCRIPTION

COMPONENTS

P/N

DESCRIPTION

Q’TY

-01

AM399/500

ANNUAL MAINTENANCE

KIT

60505029

DETECTION ELECTRODE

60701023

GASKET KERASIL 325R SQ 38X17X2

60505028

IGNITION ELECTRODE

60701022

GASKET KERASIL 325R SQ 56X22X2

-02

AM750

ANNUAL MAINTENANCE

KIT

60505029

DETECTION ELECTRODE

60701023

GASKET KERASIL 325R SQ 38X17X2

60505028

IGNITION ELECTRODE

60701022

GASKET KERASIL 325R SQ 56X22X2

-03

AM1000

ANNUAL MAINTENANCE

KIT

60505029

DETECTION ELECTRODE

60701023

GASKET KERASIL 325R SQ 38X17X2

60505028

IGNITION ELECTRODE

60701022

GASKET KERASIL 325R SQ 56X22X2

-04

AM399/500

24 MONTH FIRESIDE

INSPECTION

KIT

60505029

DETECTION ELECTRODE

60701023

GASKET KERASIL 325R SQ 38X17X2

60505028

IGNITION ELECTRODE

60701022

GASKET KERASIL 325R SQ 56X22X2

60703047

SIL. GASKET D.200 F.188 H.7,2

62801021

SYNTHETIC PLATE FILTER

-05

AM750

24 MONTH FIRESIDE

INSPECTION

KIT

60505029

DETECTION ELECTRODE

60701023

GASKET KERASIL 325R SQ 38X17X2

60505028

IGNITION ELECTRODE

60701022

GASKET KERASIL 325R SQ 56X22X2

60703047

SIL. GASKET D.200 F.188 H.7,2

62801021

SYNTHETIC PLATE FILTER

-06

AM1000

24 MONTH FIRESIDE

INSPECTION

KIT

60505029

DETECTION ELECTRODE

60701023

GASKET KERASIL 325R SQ 38X17X2

60505028

IGNITION ELECTRODE

60701022

GASKET KERASIL 325R SQ 56X22X2

60703047

SIL. GASKET D.200 F.188 H.7,2

62801021

SYNTHETIC PLATE FILTER

Summary of Contents for AM 1000B

Page 1: ...26 0288 03 28 16 USER MANUAL AM Series Natural Gas Propane Modulating Condensing Boilers Water Heaters Applies to the following AM Series models Latest Update 03 28 16 AM Boilers AM 399B AM 500B AM 750B AM 1000B AM Water Heaters Standard Models AM 399W AM 500W AM 750W AM 1000W Rapid Recovery Option AM 399RS AM 500RS AM 750RS AM 1000RS ...

Page 2: ...TALLATION 21 3 5 CLEARANCES FOR INSTALLATION AND SERVICING 21 3 6 CLEARANCES TO COMBUSTIBLE MATERIAL 22 3 7 VENT AND COMBUSTION AIR PIPING 23 3 8 PREVENTION OF COMBUSTION AIR CONTAMINATION 23 3 9 TRANSPORTING THE UNIT 23 3 10 UNPACKING AND TRANSPORTING 23 3 10 1 Transporting a Standard AM Unit 24 3 10 2 Transporting an AMR Water Heater 26 3 11 AMR BUFFER TANK INSTALLATION 27 3 11 1 AMR Buffer Tank...

Page 3: ... PREVENTION 55 6 2 GENERAL VENTING AND AIR PIPING SYSTEMS 56 6 3 MIN MAX ALLOWABLE COMBUSTION AIR AND VENT PIPING LENGTHS 58 6 4 GENERAL VENTING AND COMBUSTION AIR PIPING INSTALLATION 58 6 5 SPECIFIC VENT INSTALLATIONS 58 6 5 1 Installations Requiring High Temperature Venting 59 6 5 2 Sealing of PVC CPVC or ABS 60 6 5 3 PVC CPVC Vent Piping Materials 60 6 5 4 Air Intake and Vent Starter Pieces 61 ...

Page 4: ...R HEATER STARTUP PROCEDURE 87 8 6 GAS SUPPLY PRESSURE TEST 88 8 7 COMBUSTION CALIBRATION 90 8 8 LOST IGNITION PROCEDURE 91 8 9 MINIMUM WATER FLOW 91 8 10 HEATING SYSTEM PRESSURE TEST 92 CHAPTER 9 OPERATION 93 9 1 GENERAL OPERATION 93 9 2 FREEZE PROTECTION 94 9 3 DISPLAY ENERGY SAVING MODE 94 9 4 CONTROL PANEL DISPLAY 94 9 5 STARTUP PROCEDURE BOILERS 95 9 6 BOILER SUMMER MODE 95 9 7 ADJUSTING THE D...

Page 5: ... EXCHANGER THERMAL INSULATION 122 10 17 INSPECTING AND REPLACING THE BURNER THERMAL INSULATION 123 10 18 CHECKING FOR GAS LEAKS AFTER REASSEMBLY 125 10 19 IGNITION AND FLAME DETECTION SENSOR ELECTRODE POSITIONING 126 10 20 AIR FILTER CLEANING 127 10 21 CONDENSATE TRAP AND NEUTRALIZING RESERVOIR MAINTENANCE 128 10 22 CONTROL BOARD REPLACEMENT 130 10 23 DRAINING THE WATER FROM THE UNIT 131 10 24 WAT...

Page 6: ...AM Series Boilers and Water Heaters Page 6 of 154 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0100_0D 03 28 16 Ph 800 526 0288 GF 146 This page intentionally blank ...

Page 7: ...re easily co located to provide a boiler plant with the highest efficiency turndown and redundancy in the smallest footprint Multiple units are sequenced through the AERCO AM Cascade Manager Each unit is equipped for Modbus communication to a BAS High efficiencies and low vent temperatures mean the unit can be vented in PVC CPVC Polypropylene and AL29 4C vent materials The front access design also...

Page 8: ...AM Series Boilers and Water Heaters FORWARD Page 8 of 154 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0100_0D 03 28 16 Ph 800 526 0288 GF 146 This page intentionally blank ...

Page 9: ...f a breakdown and or malfunction of the boiler turn off the unit and do not make any attempt to repair it The boiler must be serviced exclusively by a Qualiﬁed installer using original spare parts Failure to comply with this requirement may compromise the safety of the unit WARNING Installer Read all instructions including this manual before installing Perform steps in the order given User The ins...

Page 10: ...s in the boiler system Gaskets and seals in the system may be damaged This can result in substantial property damage The manufacturer declines all liability contractual or otherwise warranty included for any damage to people animals property or this same appliance caused by Incorrect installation or failure to comply with this or any other instruction provided by the manufacturer Failure to comply...

Page 11: ...AM Series Boilers and Water Heaters CHAPTER 1 GENERAL INFORMATION OMM 0100_0D AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 11 of 154 GF 146 Ph 800 526 0288 03 28 16 OFF OFF ...

Page 12: ...perating personnel Figure 1 1 Manual Gas Shutoff Valve IMPORTANT FOR MASSACHUSETTS INSTALLATIONS Boiler Installations within the Commonwealth of Massachusetts must conform to the following requirements Boiler must be installed by a plumber or a gas fitter who is licensed within the Commonwealth of Massachusetts Prior to unit operation the complete gas train and all connections must be leak tested ...

Page 13: ...ded with a B i e AM 1000B and water heaters with a W i e AM 1000W Figure 2 1 AM Boiler or Water Heater AM 399 500 Left AM 750 AM 1000 Right 2 1 2 AM Rapid Recovery AMR Skid Option Figure 2 2 shows the AMR option comprised of an AM water heater thermal buffer tank low water cutoff LWCO recirculation loop piping and recirculation loop pump Figure 2 2 AM Water Heater with Rapid Recovery Option AM 100...

Page 14: ...ol for maximum fuel efficiency and comfort For further information on the outdoor air reset refer to Section 9 10 2 3 Intended Use Water Heaters The gas fired condensing AM Series water heaters are designed to be used for domestic hot water production Any other use is prohibited The water heaters must be connected to a storage tank for the production of domestic hot water When connecting the water...

Page 15: ...OVERVIEW OMM 0100_0D AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 15 of 154 GF 146 Ph 800 526 0288 03 28 16 2 5 AM Series Functional Schematics 2 5 1 AM 399 500 Functional Schematic Figure 2 3 399 500 Boiler Water Heater Functional Schematic ...

Page 16: ... CHAPTER 2 FUNCTIONAL OVERVIEW Page 16 of 154 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0100_0D 03 28 16 Ph 800 526 0288 GF 146 2 5 2 AM 750 Functional Schematic Figure 2 4 750 Boiler Water Heater Functional Schematic ...

Page 17: ... CHAPTER 2 FUNCTIONAL OVERVIEW OMM 0100_0D AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 17 of 154 GF 146 Ph 800 526 0288 03 28 16 2 5 3 AM1000 Functional Schematic Figure 2 5 1000 Boiler Water Heater Functional Schematic ...

Page 18: ... Transparent for Clarity MIXED BUILDING RECIRCULATION AND MAKEUP WATER RETURN TANK OUTLET TO RECIRCULATION LOOP HOT WATER OUTLET AM HEAT EXCHANGER INLET FROM WATER RETURN AND TANK GAS INLET AMR RECIRCULATION LOOP PIPING HOT WATER OUTLET FROM AM HEAT EXCHANGER TO BUFFER TANK TANK INLET FROM HEAT EXCHANGER AM SERIES WATER HEATER BUFFER TANK RECIRCULATION LOOP PUMP Warm Tank Water Cold Return Water H...

Page 19: ...asement or similar location where heavier than air gas might collect Appliances so fueled shall not be installed in an above grade under ﬂoor space or basement unless such location is provided with an approved means for removal of unburned gas This appliance is not designed for direct outdoor installation If installed outside of the structure it must be sheltered so it is protected from rain wind ...

Page 20: ...llowing factors must be considered location of vent air intakes connection to the gas supply connection to the water supply connection to the heating system connection to the electrical supply disposal of the condensation produced by the boiler connection to the room thermostat building automation system or equivalent device piping of the safety relief valve discharge connection of the outdoor tem...

Page 21: ...r liquids in the immediate vicinity of the boiler 3 4 Closet and Alcove Installation AM boilers or water heaters are not approved for installation in a closet or in an alcove site 3 5 Clearances for Installation and Servicing Figures 3 1 3 2 and 3 3 show the minimum clearances required for installation and servicing Figure 3 1 Recommended Minimum Service Clearances AM 399 AM 500 Figure 3 2 Recomme...

Page 22: ...clearances are always preferred 3 6 Clearances to Combustible Material This unit may be installed directly onto a floor of combustible material with the following clearances Table 3 1 Unit Installation Clearance Dimensions COMPONENT CLEARANCE DISTANCE Ceiling 2 inches 51 mm Front 2 inches 51 mm Rear 2 inches 51 mm Sides 2 inches 51 mm Floor 0 inches 0 mm Concentric vent 0 inches 0 mm Split vent tw...

Page 23: ...on air WARNING Ensure that the combustion air will not contain any contaminants Contaminated combustion air will damage the unit resulting in possible personal injury death or substantial property damage 3 9 Transporting the Unit Only transport the unit using the right transportation equipment such as a hand truck with a fastening belt or special equipment for maneuvering steps During transportati...

Page 24: ...er 1 Remove the lower cover A at front of the AM unit by pulling it off 2 Remove the screw washer B Figure 3 4 which fastens the pallet to the unit front Figure 3 4 Removing the Unit Front from Wood Pallet 3 Remove the screw and washer C Figure 3 5 which fastens the pallet to the unit rear Figure 3 5 Removing the Unit rear from Wood Pallet 4 Install the two factory supplied eyebolts D on the upper...

Page 25: ...opriate lifting equipment hoist the unit from the wood pallet The weight of each models are as follows Model Weight lbs AM399 300 AM500 325 AM750 500 AM1000 550 6 While unit is suspended install the leveling feet F Figure 3 7 to allow leveling the unit after installation Figure 3 7 Installing the Leveling Feet WARNING The floor onto which the unit is installed must be capable of supporting the wei...

Page 26: ...e the two 2 3 8 16 hex cap screws washers and nuts attaching the rear of the assembly skid to the pallet Figure 3 8 3 Once the assembly is disconnected from the pallet the unit may be transported using a fork lift inserted into the skid front or rear or at the sides as indicated in Figure 3 8 Figure 3 8 Transporting the AMR Rapid Recovery Water Heater CAUTION DO NOT use the lifting lugs on the AM ...

Page 27: ...or illustrations of the parts in the list AMR Buffer Tank Installation Kit P Ns AMR MODEL TANK SIZE 80 GAL TANK 119 GAL TANK AMR 399 500 P N 24484 P N 24485 AMR 750 1000 P N 24486 P N 24484 Kit Part 80 Gallon Tank for All AMR Models QTY PART NO DESCRIPTION 1 97084 18 FLEX HOSE 18 1 97084 24 FLEX HOSE 24 P N 24485 Kit Parts 119 Gallon Tank for AMR 399 500 QTY PART NO DESCRIPTION 1 97084 18 FLEX HOS...

Page 28: ...following components are provided and must be installed on the buffer tank during installation of the buffer tank to the main unit see Figure 3 10 P N 92129 T P Valve P N 62005 Cord Grip P N 49263 Thermowell P N 122848 Conductive Compound not shown P N 92129 T P Valve P N 62005 Cord Grip P N 49263 Thermowell Figure 3 10 Buffer Tank Components 3 13 Buffer Tank Installation Overview 80 gallon tank P...

Page 29: ...nsported and positioned in place DO NOT attempt to move the entire unit after the buffer tank is installed 3 15 AMR 80 Gallon Buffer Tank Installation To install the 80 gallon buffer tank to all AMR units follow the procedures below Installing the AMR 80 Gallon Buffer Tank 1 Retract threaded tank clamps to allow maximum clearance for the tank Figure 3 12 Figure 3 12 80 Gallon Tank Location and Tan...

Page 30: ... probe in the thermowell 6 Install pressure relief valve P N 92129 into upper port of tank using appropriate pipe dope such as Loctite 567 Valve outlet should point downwards Figure 3 13 Figure 3 13 AMR 80 Gallon Tank Installation and Components 7 Install the 18 Flex Hose P N 97084 18 between the AMR hot water OUTLET and the tank INLET See Figure 3 13 8 Install the 24 Flex Hose P N 97084 24 betwee...

Page 31: ...lacement as shown Figure 3 14 Adding the Extension to AMR Base for 119 Gallon Tank Installation 3 Affix extension P N 39209 to rear of AMR base by aligning tab holes of extension with holes on base sides Figure 3 14 Use lock nuts P N 56034 hex bolts P N 1216990 and washers P N 53050 to secure both sides with bolt washer on outside and nut on inside 4 Adjust threaded tank clamps Figure 3 14 to allo...

Page 32: ...AMR 119 Gallon Tank Installation and Components 10 Install a reducing coupler P N 93499 into both the tank INLET and OUTLET to reduce both connections from 2 1 2 to 2 11 Install a 3 nipple P N 90046 3 into the reducing couplers installed in the tank s INLET and OUTLET in Step 10 12 Connect 24 flex hose P N 97084 24 between nipple in the tank INLET and AMR OUTLET 13 Connect 18 or 24 see NOTE flex h...

Page 33: ...e 33 of 154 GF 146 Ph 800 526 0288 03 28 16 3 17 AM Series Supply and Return Piping Dimensions 3 17 1 Standard AM Supply and Return Piping Dimensions Standard connections and dimensions for all AM Series units are shown in Figure 3 17 Figure 3 17 AM 399 500 750 1000 Installation Connection Dimensions Models AM 750 1000 Models AM 399 500 ...

Page 34: ... dimensions for AM Series water heaters with the Rapid Recovery option are shown in Figure 3 18 Figure 3 18 AMR Installation Connection Dimensions NOTE Installation considerations for AM units with the AMR option are identical as for standard AM water heaters except where specifically noted COLD WATER INLET HOT WATER OUTLET 63 9 75 63 80 Gallon Tank 119 Gallon Tank 75 63 COLD WATER INLET 67 7 HOT ...

Page 35: ...dness must be less than 200 ppm total dissolved solids TDS Artificial Softness Do NOT use artificially softened water Artificial softening agents generally use salt which creates a chloride water chemistry a major contributor to the corrosion of the types of metals used in hydronic systems Elevated salt levels also contribute to higher conductivity levels another undesirable characteristic in hydr...

Page 36: ...used it must be used in accordance with the instructions supplied with the product Any additives added to the heating system must not be added directly inside the boiler but through the heating system piping to prevent damage to the boiler This boiler is capable of servicing multiple temperature loop systems It is the responsibility of the installer to protect the loops with lower temperature requ...

Page 37: ... system ﬂow is met otherwise the flow sensors will automatically stop the burner WARNING The National Standard Plumbing Code the National Plumbing Code of Canada and the Uniform Plumbing Code limit the pressure of the heat transfer ﬂuid to less than the minimum working pressure of the potable water system up to 30 psi maximum Also the heat transfer ﬂuid must be water or other non toxic ﬂuid having...

Page 38: ... tank to achieve proper operation Pump Recirculation pump should be sized according to AERCO s Primary Loop Design Guide C400 3 Filter Field supplied Install a filter or equivalent multipurpose strainer at the cold water inlet connection of the water heater to remove system particles from older hydronic systems and protect newer systems LWCO Low Water Cut Off Factory Supplied See Section 4 9 Insta...

Page 39: ...and abide by all local codes and regulations in force Figure 4 2 Low Water Cutoff LWCO NOTE In AM water heater systems configured with the AM Rapid Recovery Skid option the LWCO is factory installed as shown in Figure 2 6 of Section 2 5 4 SAFETY RELIEF VALVE 1 TEMPERATURE AND PRESSURE GAUGE 1 HOT WATER SUPPLY ELBOW 1 RELIEF VALVE DISCHARGE PIPING 1 pipe to within 18 of ground WATER RETURN SAFETY R...

Page 40: ... to the expansion tank manufacturer instructions for additional installation details Connect the expansion tank to an air separator only if the air separator is located on the suction side inlet of the system circulator Always locate and install the system ﬁll connection at the same location as the expansion tank connection to the system 4 11 Circulator Heating Pump AM Series boilers and water hea...

Page 41: ...y require a larger circulating pump and a revised temperature rise specification based on the water chemistry of the water to be heated Size your water system according to the following hardness guidelines to prevent scaling of the heat exchanger See Figure 4 4 for corresponding water flow If the water is 5 to 8 grain per gallon this is SOFT water and you have to size the system for a 4 ft sec min...

Page 42: ...GF 146 Figure 4 5 AM Boiler Piping Example Models AM750 1000 Shown 4 12 Domestic Hot Water System Piping with Direct Water Heater Water Heaters See Figure 4 5 for recommended piping for the AM Series water heater Refer to Figure 5 3 to wire the water heater pump An anti scald mixing valve is field supplied and is mandatory on the domestic hot water outlet of the water heater ...

Page 43: ...eased temperature water By setting the water temperature control on this water heater to obtain the increased temperature water required by these appliances you may create the potential for scald injury To protect against injury you should install a mixing valve in the water system This valve will reduce point of discharge temperature by mixing cold and hot water in branch supply lines Figure 4 6 ...

Page 44: ...ter Heaters CHAPTER 4 INSTALLATION PIPING Page 44 of 154 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0100_0D 03 28 16 Ph 800 526 0288 GF 146 Figure 4 7 AM Water Heater Piping Example Models AM 750W 1000W Shown ...

Page 45: ...e flue exhaust outlet A through pipe to condensate neutralizer tank drains through pipe C Figure 4 8 and E Figure 4 9 and empties into the floor drain or drain pan F Figure 4 9 The condensation disposal system must slope the condensate tubing down and away from the boiler into a drain or drain pan See Figure 4 9 Condensate from the boiler will be slightly acidic around pH 4 The neutralizing tank s...

Page 46: ...526 0288 GF 146 Figure 4 9 Condensate Tank Draining A condensate removal pump is required if the boiler is below the drain When installing a condensate pump select one approved for use with condensing boilers and furnaces The pump should have an overﬂow switch to prevent property damage from condensate spillage E Condensate Drain Pipe F Floor Drain or Drain Pan E F ...

Page 47: ... switch 15 amp recommended as required by prevailing codes To connect the electrical line voltage power supply cable refer to Figure 5 1 Figure 5 1 Line Voltage Connection Figure 5 2 Boiler Electrical Junction Box Connections W Optional DHW through an Indirect Tank Indirect tank sensor Secondary pump relay L1 120VAC VOLTAGE TERMINALS 24VDC VOLTAGE TERMINALS Secondary pump relay N max 3A Indirect D...

Page 48: ...nect the 0 10 VDC supply between terminals 22 and 23 see Figure 5 3 in the electrical junction box and the CH mode parameter 2003 in the Installer Menu per Section 9 16 must be set to 4 four When configured this way the heater supply temperature is controlled by the analog input 0 10 VDC as shown in Figure 5 4 where If the input voltage stays below 1 5V the heater stays OFF If the input voltage in...

Page 49: ...m 5 1 4 MODBUS Interface Connections Boilers and Water Heaters The AM Series models 500 750 and 1000 are factory supplied with a Communications Module the 399 model can be equipped with one as an option This MODBUS interface can be connected to drive the unit from a building management device Refer to the AM Series MODBUS User Manual GF 146 MB which is available from AERCO technical support and th...

Page 50: ...hat parameter 2003 is set to 0 zero NOTE The maximum cable length permitted is 32 feet 10 meters For longer lengths up to 300 feet 100 meters a shielded cable with the shield connected to the ground must be used Figure 5 5 Enable Disable Electrical Connection to Boiler Terminals 10 and 11 5 2 2 Installing the Outdoor Temperature Sensor Boilers The outdoor temperature sensor is supplied with the bo...

Page 51: ... wires conduct 24 VAC they must never be run through conduits containing 120 VAC power wires or an electrical shock hazard will exist 5 2 3 Indirect Water Heater Connection Boilers To connect an indirect water heater to the boiler perform the following steps Connecting the Boiler to an Indirect Water Heater 1 Ensure that water connections are first made per examples in Figures 4 6 or 4 8 2 Open th...

Page 52: ...of a two conductor cable with a minimum cross section of 18 AWG to the aquastat and run the cable to the water heater electrical junction box 4 Connect the aquastat cable leads to the 10 and 11 terminals as shown in Figure 5 5 5 Access the Installer Menu Section 9 16 and ensure that parameter 2003 is set to 0 zero 6 The storage tank pump must be connected to terminals 113 and 114 of the electrical...

Page 53: ...ON ELECTRICAL OMM 0100_0D AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 53 of 154 GF 146 Ph 800 526 0288 03 28 16 Figure 5 6 AMR Recirculation Pump Pump Relay and LWCO Wiring Other Wiring Not Shown for Clarity AM Water Heater Wiring Terminals ...

Page 54: ...es Boilers and Water Heaters CHAPTER 5 INSTALLATION ELECTRICAL Page 54 of 154 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0100_0D 03 28 16 Ph 800 526 0288 GF 146 This page intentionally blank ...

Page 55: ...the unit possibly causing a dangerous condition Ensure that the combustion air will not contain any of the following contaminants Permanent wave solutions Chlorinated waxes cleaners Chlorine based swimming pool chemicals Calcium chloride used for thawing Sodium chloride used for water softening Refrigerant leaks Paint or varnish removers Hydrochloric acid muriatic acid Cements and glues Antistatic...

Page 56: ...Gas Code ANSI Z223 1 NFPA 54 or section Venting Systems and Air Supply for Appliances of the CAN CSA B149 1 Natural Gas and Propane Installation code or applicable provisions of the local building codes All vent pipes must be mechanically fixed The exhaust vent and the air inlet lines must be supported to prevent sagging To do this use a suitable pipe clamp to support the lines Pipe clamps shall s...

Page 57: ...aters CHAPTER 6 INSTALL VENT COMBUSTION AIR PIPING OMM 0100_0D AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 57 of 154 GF 146 Ph 800 526 0288 03 28 16 Figure 6 1 Acceptable Vent Air Piping Methods for AM Series Units ...

Page 58: ...ure the vent and air piping and the combustion air supply comply with these instructions regarding vent system air system and combustion air quality Inspect finished vent and air piping thoroughly to ensure all are airtight and comply with the instructions provided and with all requirements of all applicable codes WARNING Failure to provide a properly installed vent and air system will cause sever...

Page 59: ...VC venting is not allowable These kits are automatically configured in buy aerco Factory Menu Settings and Fuse Replacement for SST Venting 1 Refer to Appendix B for how to access navigate and choose settings in the Factory Menu 2 Navigate to the 3100 parameter and change to SST for stainless CPVC for cPVC and PP for polypropylene venting which changes the vent temperature threshold from 203 F to ...

Page 60: ...let pipe must be resealed to ensure that combustion air will be free of contaminants and supplied in proper volume 6 5 3 PVC CPVC Vent Piping Materials Installation must comply with local requirements and with the National Fuel Gas Code ANSI Z223 1 for U S installations or CSA B149 1 for Canadian installations For installation in Canada vent pipe system must be certified to ULC S636 Installation o...

Page 61: ...piping 3 deep into the adapters 3 Tighten each adaptor hose clamp Fig 6 2 to secure each adaptor to its respective piping 4 Drill a 1 4 hole into the exhaust outlet piping in approximately the position as shown in Figure 6 2 This port will be used as a combustion analysis port during the combustion calibration procedure described in Section 8 2 Procure a suitable cap to plug this port when it is n...

Page 62: ...ubricants on joints Never use hydrocarbons based lubricants because they would destroy gaskets 6 5 5 Single Pipe Venting Room Air Combustion Commercial applications utilizing this heater may be installed with a single pipe carrying the flue products to the outside while using combustion air from the equipment room In this case the following conditions and considerations must be followed Utilizing ...

Page 63: ... affect performance or cause recirculation such as inside building corners near adjacent buildings or surfaces window wells stairwells alcoves courtyards or other recessed areas f Do not terminate above any door or window Condensate can freeze causing ice formations g Locate or guard vent to prevent condensate damage to exterior finishes 3 The vent piping must terminate in an elbow pointed outward...

Page 64: ...ation Two pipes Installation must comply with local requirements and with the National Fuel Gas Code ANSI Z223 1 for U S installations or CSA B149 1 for Canadian installations CAUTION A gas vent extending through an exterior wall shall not terminate adjacent to a wall or below building extensions such as eaves parapets balconies or decks Figure 6 5 Sidewall Termination of Air and Vent Pipes NOTE M...

Page 65: ...ated in the room 6 5 10 One Permanent Opening Method One permanent opening commencing within 12 inches 300 mm of the top of the room shall be provided The appliances shall have clearances of at least 1 inch 25 mm from the sides and back and 6 inches 150 mm from the front of the appliance The opening shall directly communicate with the outdoors or shall communicate through a vertical or horizontal ...

Page 66: ...not extend exposed vent pipe outside of the building more than what is shown in Figure 6 5 Condensate could freeze and block vent pipe 6 5 13 Multiple Vent and Air Terminations When installing multiple air and vent terminations ensure the following Terminate each vent air connection as shown in Figure 6 7 All vent pipes and air inlets must terminate at the same height Place wall penetrations to ob...

Page 67: ...Ph 800 526 0288 03 28 16 Figure 6 7 Two Pipe Multi Unit Air and Vent Sidewall Termination 6 5 14 Sidewall Termination Concentric Vent A concentric vent termination must terminate outside the structure and must be installed as shown in Figure 6 8 The termination opening must be protected from rain as shown in Figure 6 9 Figure 6 8 Concentric Sidewall Termination Clearances ...

Page 68: ...tioning equipment or be objectionable b The flue products will form a noticeable plume as they condense in cold air Avoid areas where the plume could obstruct window views c Prevailing winds could cause freezing of condensate and water ice buildup where flue products impinge on building surfaces or plants d Avoid possibility of accidental contact of flue products with people or animals e Do not te...

Page 69: ...88 03 28 16 6 5 16 Multi venting Sidewall Terminations When two or more direct vent appliances are vented near each other each appliance must be individually vented and vent terminations may be installed as shown in Figure 6 10 It is important that vent terminations be made as shown to avoid recirculation of flue gas Figure 6 10 Concentric Sidewall Multiple Unit Termination Clearances ...

Page 70: ...t of a building within 10 horizontal feet 3 The vent must terminate in a tee or acceptable rain cap 4 The air piping must terminate in a down turned 180 return pipe no further than 2 feet from the center of the vent pipe This placement avoids recirculation of flue products into the combustion air stream 5 The vent piping must terminate at least 1 foot above the air intake The air inlet pipe and ve...

Page 71: ...oles to provide the minimum spacing shown in Figure 6 11 and listed in Section 6 5 16 6 Follow all local codes for isolation of vent pipe when passing through floors ceilings and roofs 7 Provide flashing and sealing boots sized for the vent pipe and air pipe 6 5 19 Installing Vertical Vent and Air Roof Terminations Install vent and air terminations into a roof as follows Installing Vertical Vent a...

Page 72: ...rtical Multiple Vent and Air Roof Terminations 1 When terminating multiple units terminate each vent air connection as shown in Figure 6 12 2 Place roof penetrations to obtain minimum clearance of 12 inches between edge of air intake elbow and adjacent vent pipe of another appliance for U S installations 3 The air inlet is part of a direct vent connection It is not classified as a forced air intak...

Page 73: ... concentric vent air terminations using the following guidelines 1 The total length of piping for vent or air must not exceed the limits given in the Section 6 3 2 The concentric terminal must terminate at least 3 feet above the highest place in which the vent penetrates the roof and at least 2 feet above any part of a building within 10 horizontal feet 3 Locate termination so it is not likely to ...

Page 74: ...ilers and Water Heaters CHAPTER 6 INSTALL VENT COMBUSTION AIR PIPING Page 74 of 154 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0100_0D 03 28 16 Ph 800 526 0288 GF 146 This page intentionally blank ...

Page 75: ...essure is between 3 and 13 individual regulators are recommended on every unit but not required NOTE For installation in Massachusetts an individual gas regulator is required on every unit regardless of incoming gas pressure 7 2 Connection of Gas Supply Piping Connect the gas supply to the unit as follows Connecting the Gas Supply to the Unit 1 Refer to Figure 7 1 for connections necessary to pipe...

Page 76: ...ting of the gas supply piping system at test pressures equal to or less than 1 2 PSIG 3 5 kPa c The appliance and its gas connection must be leak tested before placing it in operation 6 Use pipe sealing compound compatible with propane gas Apply sparingly only to male threads of the pipe joints so that pipe dope does not block gas flow WARNING Do not attempt to support the weight of the piping wit...

Page 77: ...00 N A 148 304 455 877 1400 2470 5040 125 N A 131 269 403 777 1240 2190 4460 150 N A 119 244 366 704 1120 1980 4050 175 N A N A 224 336 648 1030 1820 3720 200 N A N A 209 313 602 960 1700 3460 250 N A N A 185 277 534 851 1500 3070 NOTE Maximum pipe capacity is based on a 0 60 specific gravity gas at a pressure of 0 5 PSIG and a 0 3 W C pressure drop 7 4 Natural Gas Supply Pressure Requirements Ins...

Page 78: ...nformation For installations at higher altitudes in the United States follow local codes or in the absence of local codes follow ANSI Z223 1 NFPA No 54 The National Fuel Gas Code and check and adjust the CO2 level following Section 8 7 7 9 Conversion from Natural gas to Propane Gas The gas conversion must be performed on each burner present inside the unit The gas conversion shall be performed by ...

Page 79: ...d parameter Parameter 3002 will begin to blink in the display Now the value can be changed using the and buttons 5 Using Table 3 5 select the right parameter value for the unit you are converting to propane gas or to natural gas Table 7 2 Natural Gas and Propane Gas Settings 6 Press RESET button once to save the new value 7 Turn the power OFF to the unit 8 Close the manual gas shut off valve 9 Rem...

Page 80: ...ure 7 2 17 Turn the power ON to the unit 18 Turn completely counter clockwise screw E in Figure 7 5 19 Check the gas supply pressure per Section 8 6 The minimum gas supply pressure must not be less than 3 W C 7 6 mbar and the maximum gas supply pressure must not be higher than 13 W C 33 mbar 20 Verify the CO2 rate and its adjustment per Section 8 7 Figure 7 2 Dismantling the Gas Valve Figure 7 3 L...

Page 81: ...f present 6 Disconnect plug B from connector C 7 Connect plug B to connector D 8 Repeat Step 1 through Step 20 of the previous instructions Gas Rating Conversion of Master Burner 9 Ensure power is still OFF to the unit Burner 4 if present 10 Disconnect plug B from connector D 11 Connect plug B to connector E 12 Repeat Step 1 through Step 20 of the previous instructions Gas Rating Conversion of Mas...

Page 82: ...tional Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0100_0D 03 28 16 Ph 800 526 0288 GF 146 Figure 7 6 Changing the Display Connections AM 750 1000 Shown Figure 7 7 PROPANE LP GAS Label Figure 7 8 NATURAL GAS label NOTE In AM 399 500 models the BURNER 1 Master is the lower one and BURNER 2 the upper one ...

Page 83: ...this manual and all other documentation included with the heater Make sure that the user understands never to tamper with gas control settings and the risk of CO poisoning should an unauthorized individual do so Make sure that the user knows how to adjust temperatures and controls 8 1 1 Filling the Condensate Neutralizer The condensate neutralizer tank is positioned inside the heater as shown in F...

Page 84: ...m is sized To temporarily decrease the minimum water pressure set parameter 3022 to the desired value See Appendix B 3 Check that there is no water leaking from the ﬁttings If there is the leaks must be repaired 4 Check the pressure gauge during the purging process If the pressure has dropped re open the ﬁll valve to bring the pressure back to the desired value If it was changed be sure ro set par...

Page 85: ...he fire department 8 2 1 Confirming the Unit s Gas Type The type of gas and the gas supply pressure that the unit is set up for is listed on the rating label The AM Series boilers and water heaters can operate using one of the following two gases NATURAL GAS o Maximum supply pressure 13 W C 33 0 mbar o Minimum supply pressure 3 W C 7 6 mbar PROPANE LP GAS o Maximum supply pressure 13 W C 33 0 mbar...

Page 86: ... information 1 Open the manual gas shut off valve Figure 7 1 2 Turn the unit power switch to ON item T in Figure 8 1 3 The boiler will ﬁre only when there is a call for heat and the heating temperature setting is higher than the actual supply temperature Hold buttons or to select the desired heating temperature If the external temperature sensor is connected see Section 5 2 2 check that the calcul...

Page 87: ...ater do the following Water Heater Startup Procedure NOTE Before operation it may be necessary to check the 2000 and 3000 level parameters on each control board See section 8 16 and Appendix B for further information 1 Open the manual gas shut off valve Figure 7 1 2 Turn the unit power switch to ON Figure 8 1 NOTE The temperature setpoint is adjusted to its lowest temperature position when shipped...

Page 88: ... Supply Pressure Test 1 Close the manual gas shut off valve Figure 7 1 2 Remove the front cover Figure 10 1 3 Turn the screw in pressure port D shown in Figure 8 2 three turns counterclockwise Figure 8 2 Gas Valve 4 Connect a manometer with graduations of at least 0 1 W C 0 25 mbar to the inlet gas port D shown in Figure 8 2 on unit model 399 to 1000 choose the pressure port D from any gas valve p...

Page 89: ...meter to make sure the gas supply pressure does not drop below 3 W C 7 6 mbar If the gas supply pressure is lower than 3 W C it means that your inlet gas line or your gas pressure regulator is not correctly sized CAUTION DO NOT adjust the screw F Figure 8 2 This screw is factory set for the correct gas flow and outlet pressure Attempting to alter the gas valve setting could result in damage to the...

Page 90: ...so follow the vent pipe manufacturers instruction 2 Keep the boiler or water heater in stand by by pushing either button for water heaters or for boilers until the word OFF is seen in the display 3 Gain access to the Installer menu and set parameter 2201 to HIGH see Section 9 16 so the Burner 1 Master will run for 20 minutes at high fire input then generate a demand for heat by pressing the button...

Page 91: ...lled with the unit at high fire check that there are no leaks and that the cap is mechanically secure 8 8 Lost Ignition Procedure If the burner will not stay lit long enough to perform combustion calibration perform the following steps Lost Ignition Procedure 1 Ensure the gas pressure to the unit is between 3 13 W C ensure that parameter 3002 is set correctly on each burner and that the gas valve ...

Page 92: ...ling valve and check the pressure on the pressure gauge M of Figure 8 1 Err 59 will disappear when the pressure is back at the right value To prevent accidental relief valve openings ﬁll the heating circuit slowly This value is adjustable via parameter 3022 CAUTION Continual fresh make up water will reduce boiler life Mineral buildup in the heat exchanger reduces heat transfer overheats the stainl...

Page 93: ...ameters by means of using the User Menu see Section 9 15 and the Installer Menu see Section 9 16 During use the part of the display labeled N in Figure 9 1 shows the supply temperature if the boiler is supplying heat or the indirect water heater temperature if boiler is supplying a tank load The part of the display labeled M shows the pressure of the heating system The other icons in the display s...

Page 94: ...at alarms the user in case the unit room will reach a temperature near 35 F 2 C Once the boiler has reached a temperature of 50 F 10 C the heating pump will automatically turn on If the temperature falls below 41 F 5 C the burner will light to prevent the boiler from freezing If the boiler will not be used for long time it should be drained per Section 10 23 9 3 Display Energy Saving Mode The disp...

Page 95: ...will shut down and the display will show Loc 01 together with icon If the boiler goes into any lockout or blocking error the display will show icon and the corresponding burner icon or will blink To restore the normal operating condition press RESET key one time and the display will show the type of lockout Press the RESET key again To return to normal display mode press and hold the RESET button ...

Page 96: ...r constant setpoint control The heating system type can be changed by accessing the Installer Menu per Section 9 16 and changing the 2003 parameter One of the following heating modes can be selected 2003 00 Constant setpoint with remote enable see Section 9 16 2003 01 Outdoor reset with remote enable see Section 9 16 An outdoor temperature sensor is required for this setting 2003 02 Outdoor reset ...

Page 97: ...oor temperature you want the heating service to the minimum capacity Suggested value is 64 F 18 C 2024 Spring supply temperature Is the supply temperature correspondent to the Spring outdoor temperature parameter 2023 Suggested values are 86 F 30 C for ﬂoor radiant panels or 108 F 42 C for radiators heating systems 9 10 2 Outdoor Reset Activation Once selected reset adjustment is completely automa...

Page 98: ... electric power to the boiler 3 If the display shows code Err 65 it means that the polarity has not been observed between phase and neutral Call service department to restore do NOT attempt to repair it 4 Press key and to setup the storage tank water temperature desired then press RESET key to save the change 5 The ﬂame control will start up the burner a If the burner fails to ignite within 60 sec...

Page 99: ...sed the display shows the domestic hot water setpoint being selected The range within which the domestic hot water can be set is from 104 F 40 C to 140 F 60 C The right temperature to keep storage and save energy is the lowest possible temperature compatible with the amount of water you need Start with a temperature of 120 F and check if this is sufficient If not gradually increase the temperature...

Page 100: ... 1011 State of the DHW pump ON OFF 1012 Calculated CH setpoint when outdoor sensor s activated only for 199 and 250 mode F 1040 Burner 1 Actual Fan speed rpm min 1041 Burner 1 Ignition fan speed rpm min 1042 Burner 1 Low power fan speed rpm min 1043 Burner 1 High power fan speed rpm min 1051 Burner 1 Last lockout number 1052 Burner 1 Last Blocking error 1053 Burner 1 Number of flame failures 1055 ...

Page 101: ... Once the desired parameter is displayed it can be selected for editing by pressing the RESET button once the displayed value will start blinking and then using the and buttons to change the value up or down 4 To confirm the new value press and release the RESET button before moving to the next parameter 5 To exit the Installer Menu press and hold RESET button for more than 5 seconds until the ico...

Page 102: ...0 TIME DHW has priority to CH during DHW max priority time 2063 1 OFF CH always has priority to DHW 2 ON DHW always has priority to CH 2 N A 2100 Display delay to shut off min 0 to 30 5 5 2101 MULTIBURNER Emergency mode If sensor 1102 fail no or yes Yes Yes 2102 MULTIBURNER Emergency setpoint F 68 to 149 113 113 2103 MULTIBURNER start delay time sec 1 to 900 180 15 2104 MULTIBURNER stop delay time...

Page 103: ...ntil the word init is displayed in the control panel display or until the control panel display begins to show the 3000 parameters then release the RESET button and then the button 5 Press the and buttons to scroll up or down through the parameters 6 To change a displayed parameter press the RESET button The parameter value will blink 7 Press the and buttons to cycle up or down through the paramet...

Page 104: ...8 N A 48 48 48 48 48 3007 Condensate blocked drain detector EnAb Enabled dISA Disabled Enab Enab dISA Enab dISA 3008 Flue gas detector SEnS Sensor StCH Switch SEnS SEnS SEnS SEnS SEnS 3009 Outdoor thermistor type 10 10kohms 12 12kohms 10 10 10 10 10 3010 Other thermistor type 10 10kohms 12 12kohms 10 10 10 10 10 3011 Pump MODE 0 Local pump 1 N A 2 N A 3 N A 0 0 0 0 0 3012 DHW mode 0 no DHW 1 DHW s...

Page 105: ...his parameter overrules 3015 parameter 68 F to 194 F 179 F 179 F 179 F 179 F 179 F 3018 Minimum supply 68 F to 194 F 89 F 89 F 89 F 89 F 89 F 3020 Type of water ﬂow sensor 0 N A 1 DN8 2 DN 10 3 DN 15 4 DN 20 5 DN 25 3 4 4 4 4 3022 Minimum water pressure 0 to 74 PSI 14 14 14 14 14 3035 Minimum water ﬂow 0 to 26 4 GPM 3 9 3 9 3 9 3 9 3 9 3050 Number of slave burners 0 to 3 3 399 1 500 1 750 2 1000 3...

Page 106: ... the RESET button once and the lockout error number will show in the display 3 To attempt to reset the unit press and hold down the RESET button for at least 5 seconds which should return the display to its normal function 4 If the unit cannot be reset in this way consult the table of Lockout error messages below and attempt to diagnose and resolve the problem before attempting to reset the unit a...

Page 107: ...to inform the manufacturer to prevent serious damage and a possible dangerous condition Loc 06 Safety relay open error Replace the power control board Loc 07 Safety relay closed error Replace the power control board Loc 11 Blocking error over 20 hr Press RESET button to see the Blocking error reference and proceed follow it Loc 12 Fan error a Check for 120VAC power connection of the fan b Check PW...

Page 108: ...ress the RESET button once and the lockout error number will show in the display 3 To resolve the error consult the table of Error Err messages in the chart below and attempt to diagnose and resolve the problem 4 To return the display to normal function press and hold down the RESET button for at least 5 seconds Blocking Error Messages ERR DESCRIPTION CHECKS SOLUTIONS Err 0 One sensor is out of ra...

Page 109: ... no communication with the a Check frequency signal is between 55 and 65Hz b Check the ground connection between ground and neutral it must a If out of range consult your electrical supplier b If the ground connection is not correct ask your electrical supplier to investigate Alternately replace the power control board Err 65 Hot neutral reversed Check supply voltage polarity Reverse supply voltag...

Page 110: ...ication failure Bus communication interrupted a burner is not working c Check for bus communication d Restore the burner that has its light off e Check parameter 3001 on each burner f Check parameter 3050 on each burner g Check S4 switch on each burner NO CONN Microprocessor is in lockout a Check if water pressure sensor wires are in short circuit b Check if water flow meter wires are in short cir...

Page 111: ... perform the following Shutting Down the Unit 1 Turn the unit power switch to the OFF position 2 Turn off all electrical power to the unit 3 Close the manual shut off valve Figure 9 3 by turning the valve handle clock wise Do not force Figure 9 3 Gas Safety Shut Off Valve Do not drain the system unless exposure to freezing temperatures will occur Do not drain the system if it is ﬁlled with an anti...

Page 112: ...AM Series Boilers and Water Heaters CHAPTER 9 OPERATION Page 112 of 154 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0100_0D 03 28 16 Ph 800 526 0288 GF 146 This page intentionally blank ...

Page 113: ...NICIAN USER MAINTENANCE Annual Startup and Maintenance Address reported problems Check all piping for gas leaks Verify ﬂue and air lines in good condition and sealed tight Check system water pressure system piping expansion tank Check control settings Check ignition and ﬂame sense electrodes Check wiring and connections Perform start up checkout and performance veriﬁcation Flame inspection Check ﬂ...

Page 114: ... unit leaks Continual fresh makeup water will reduce boiler life Minerals can build up in sections reducing heat transfer overheating heat exchanger and causing heat exchanger failure Leaking water may also cause severe property damage 10 4 Ignition and Flame Sensor Inspection To inspect and maintain the ignition and flame sensor perform the following Ignition and Flame Sensor Inspection 1 Remove ...

Page 115: ... by the user WARNING Failure to re inspect the relief valve as directed could result in unsafe pressure buildup and a dangerous condition 10 10 Unit Vicinity Inspection The following are NOT allowed to be in the vicinity of the unit or the flue exhaust system Combustible ﬂammable materials Do not store combustible materials gasoline or any other ﬂammable vapors or liquids near the unit or exhaust ...

Page 116: ...signs of weeping or leakage If you detect signs of leakage immediately contact your qualiﬁed service technician to inspect the boiler and system Ensure there is sufficient neutralizer media It is recommended to replace this media annually WARNING Have leaks ﬁxed at once by a qualiﬁed service technician 10 13 Low Water Cutoff Test If an LWCO is installed it should be tested Testing the low water cu...

Page 117: ...ver A 2 Remove two Front Cover screws B 3 Pull back the upper part of Front Cover C for 2 inches then pull it up for one inch and remove it from the unit 4 Pull back upper part of Bottom Cover D for 2 inches then pull it up for one inch and remove it from the unit 5 To gain access to the junction box a Remove the Junction Box Cover screw E at rear of cover b Remove Junction Box cover F Figure 10 1...

Page 118: ...Heat Exchanger WARNING Before proceeding to the next step verify that the electrical supply to the heater and any other electrical supply near the heater is off Verify that the manual gas shut off valve is closed 1 Follow the steps in Section 10 14 to gain access to the internal components 2 Prepare a suitable cover for the burner so that no dirt water or other foreign objects can fall into the bu...

Page 119: ...the air inlet elbow connector B Figure 10 3 in the up direction 6 Pull in the left direction C the air inlet silencer and remove it from the fan Figure 10 3 Removing the Air Inlet Silencer 7 Unscrew nut H Figure 10 4 Take note of the gasket between nut H and the gas valve and remove the electrical plug from the gas valve Figure 10 4 Removing the Nut Spring from the Gas Valve 8 Remove spring A as i...

Page 120: ...6 0288 GF 146 Cleaning the Burner and Primary Heat Exchanger Continued 9 Remove the gas valve from its position see Figure 10 5 Note the O ring L per Figure 6 5 Figure 10 5 Removing the Gas Valve 10 Unscrew the four nuts B in Figure 10 6 11 Remove the entire fan and burner assembly detail C as shown in Figure 10 6 Figure 10 6 Removing the Fan and Burner Assembly ...

Page 121: ...ile performing the next step carefully wash only the inside of the combustion chamber and do not get water on the outside of the combustion chamber opening Failure to comply with this warning can cause extensive property damage or a dangerous condition 15 Using only water wash the inside of the combustion chamber The water will drain into the condensate drain 16 Reassemble the components by perfor...

Page 122: ...tructions in section 10 15 in order to remove the fan and burner assembly from the heat exchanger 2 Unscrew nut from the thermal insulation see Figure A 3 Use a screwdriver toremove the thermal insulation 4 Prepare the screw and the washer to fix the new thermal insulation see Figure B Figure A Screw Thermal Insulation Figure B Screw Washer 5 Align the bolt holes in the heat exchanger detail B in ...

Page 123: ... replacement procedure must be repeated on each burner module in the unit Replacing the BURNER Thermal Insulation 1 Follow Steps 1 through 11 of the instructions in section 6 1 16 in order to remove the fan and burner assembly from the heat exchanger 2 Unscrew the screws holding the electrodes in place see Figure E 3 Remove both the ignition and flame detection electrodes see Figure F Figure E Rem...

Page 124: ...Assembly the ignition and detection electrodes paying attention to the correct position of the red gasket shown with arrows in Figure K 9 Screw the electrodes in place see Figure L Figure K Reassemble the Electrodes Figure L Tighten the Electrodes 10 Before reinstalling the burner clean the surface on which the gasket will sit shown with arrows in Figure M to ensure a good seal 11 Install the reas...

Page 125: ...88 03 28 16 10 18 Checking for Gas Leaks after Reassembly Once the unit is reassembled and the electrical connection restored open the manual gas shut off valve and check the unit for gas leaks Checking for Gas Leaks After Reassembly Use an approved leak detention method to check all junctions shown with arrows A through E in Figure O Figure O Leak Check Locations ...

Page 126: ... Flame Detection Electrode Positioning To insure correct functioning of the burner the distances listed below should be carefully veriﬁed by hand using calipers The distance between the ignition electrodes A and B must be between 0 08 in 2 mm and 0 10 in 2 5 mm The distance of the ignition electrodes to the burner surface must be between 0 20 in 5 0 mm and 0 22 in 5 5 mm The distance of the ﬂame d...

Page 127: ...tion of the unit resulting in system malfunctions To clean the air filter perform the following Cleaning the Air Filter 1 Follow the steps in Section 10 14 to gain access to the internal components 2 Pull down with a rotating motion the air ﬁlter B as per Figure 10 8 3 Pull out the air ﬁlter and remove it from the unit 4 Clean the surface of the air ﬁlter using compressed air 5 Reassemble the air ...

Page 128: ...ction can be reduced to every six months or every year depending on the readings obtained compared to local water authority requirements The neutralizing media should be replaced when the pH level drops below the minimum level of the local water authority For replacement media contact AERCO To inspect and maintain the condensate system perform the following Condensate System Inspection and Mainten...

Page 129: ...tion tank must be ﬁlled with water to prevent ﬂue gas emissions from escaping during unit operation Failure to comply with this requirement can result in dangerous levels of carbon monoxide 9 Open the manual gas shutoff valve 10 Restore electrical power to the unit and return to service WARNING The condensate neutralizer tank MUST be installed correctly into the unit as shown in Figure 4 8 If you ...

Page 130: ...in order to resume the function of the unit To do so perform the following Replacing the Burner 1 Master Control Board 1 Turn off all electrical power to the unit 2 Follow the steps in Section 10 14 to remove the front cover 3 Refer to Figure 10 11 and disconnect plug B plug coming from display from plug A plug coming from Burner 1 Master 4 Disconnect all other plugs from the Burner 1 Master contr...

Page 131: ...ould drive the unit correctly 10 23 Draining the Water from the Unit To drain the water from the unit follow the steps below Draining the Water from the Unit 1 Cool down the unit by setting the control temperature to the maximum see Section 9 2 for boilers and Section 9 14 for water heaters and wait the temperature gauge shows less than 104 F 40 C 2 Turn OFF all electrical power off to the heater ...

Page 132: ...ion the electrical resistance between the sensor wires must correspond with the values shown in Figure 10 12 for both boilers and water heaters Figure 10 12 Water and Flue Temperature Sensor Curve 10 25 Outdoor Temperature Sensor Boilers Only An outdoor temperature sensor can be connected to the boiler see Section 5 2 2 The electrical resistance existing between the sensor wires must correspond wi...

Page 133: ...eakage or damage is present take preventive measures and shut down the system immediately then contact AERCO technical support for information about repair or replacement of any parts or components See Chapter 12 for a diagram and parts list of all AMR option spare parts 10 26 2 Buffer Tank Anode Rods Anodes should be checked and cleaned every six months The AMR buffer tank supplies 25 grams of an...

Page 134: ... 60505028 IGNITION ELECTRODE 3 60701022 GASKET KERASIL 325R SQ 56X22X2 3 03 AM1000 ANNUAL MAINTENANCE KIT 60505029 DETECTION ELECTRODE 4 60701023 GASKET KERASIL 325R SQ 38X17X2 4 60505028 IGNITION ELECTRODE 4 60701022 GASKET KERASIL 325R SQ 56X22X2 4 04 AM399 500 24 MONTH FIRESIDE INSPECTION KIT 60505029 DETECTION ELECTRODE 2 60701023 GASKET KERASIL 325R SQ 38X17X2 2 60505028 IGNITION ELECTRODE 2 ...

Page 135: ...AM Series Boilers and Water Heaters CHAPTER 10 MAINTENANCE OMM 0100_0D AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 135 of 154 GF 146 Ph 800 526 0288 03 28 16 10 27 1 Wiring Diagram ...

Page 136: ...AM Series Boilers and Water Heaters CHAPTER 10 MAINTENANCE Page 136 of 154 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0100_0D 03 28 16 Ph 800 526 0288 GF 146 ...

Page 137: ...enting system ft 120 120 120 120 CO Carbon monoxide with natural gas ppm 150 150 150 150 CO Carbon monoxide with LP gas ppm 250 250 250 250 NOx ppm 20 20 20 20 CO2 Carbon dioxide for Natural gas at high 8 4 to 8 7 8 8 to 9 1 8 8 to 9 1 8 8 to 9 1 CO2 Carbon dioxide for Natural gas at low 8 4 to 8 7 8 8 to 9 1 8 8 to 9 1 8 8 to 9 1 CO2 Carbon dioxide for LP gas at high fire 9 5 to 10 9 5 to 10 9 5 ...

Page 138: ...rior Ultonium Glass Lining Porcelain Enamel Exterior Baked Enamel Steel Jacket Baked Enamel Steel Jacket Insulation 2 R 12 5 Open Cell Foam 2 R 12 5 Open Cell Foam Supports Sits on Shell Sits on Shell Capacity 80 Gal 119 Gal Weight 192 Lbs 225 Lbs Material Specifications Shell Carbon Steel Carbon Steel Heads Carbon Steel Carbon Steel Couplings Carbon Steel Carbon Steel Jacket 24 Gauge Steel 24 Gau...

Page 139: ...RTS OMM 0100_0D AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 139 of 154 GF 146 Ph 800 526 0288 03 28 16 CHAPTER 12 SPARE PARTS DRAWINGS LISTS 12 1 AM 399 500 Spare Parts Drawings Figure 12 1 AM 399 500 General Assembly Parts Drawing 1 of 2 ...

Page 140: ... and Water Heaters CHAPTER 12 SPARE PARTS Page 140 of 154 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0100_0D 03 28 16 Ph 800 526 0288 GF 146 Figure 12 2 AM 399 500 General Assembly Parts drawing 2 of 2 ...

Page 141: ...rs and Water Heaters CHAPTER 12 SPARE PARTS OMM 0100_0D AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 141 of 154 GF 146 Ph 800 526 0288 03 28 16 Figure 12 3 AM 399 500 Burner Fan Assembly Parts Drawing ...

Page 142: ...25 15 61405316 D 125 H 809 COLLECTOR 2 EXCHANGERS 16 60702097 GASKET D 119 H 16 I 94 17 60702096 GASKET D 66 H 16 I 45 18 60502085 SINGLE GREY BOARD CLAMP 18 60502086 ON FLOOR YELLOW GREEN BOARD CLAMP 18 60502101 SINGLE BLUE BOARD CLAMP 19 60506031 BLACK 2 POLES SWITCH 20 60507059 CONNECTION BOARD 160X100 21 62113046 PRESSURE SWITCH ON 3 2 IN W C 22 62801021 SYNTHETIC PLATE FILTER 23 61405326 CAP ...

Page 143: ... SENSOR 58 62621153 COPPER TUBE D28 F F 1 1 4 1 1 4 RIT 2 Models WITH Motorized Valve 58 62621186 COPPER TUBE D28 F F 1 1 4 1 1 4 Models WITHOUT Motorized Valve 59 61202043 SPHERE 2 WAYVALVE Models WITH Motorized Valve 60 61203024 2 WAY VALVE MOTOR Models WITH Motorized Valve 61 62621152 COPPER TUBE D28 F F 1 1 4 1 1 4 RIT Models WITH Motorized Valve 62 60801065 6X12MM TC CR SCREW 63 62113045 PRES...

Page 144: ...500W H Only 97 60434036 EXCHANGERS BRACKET 98 60406137 SHAPED BRACKET 67X54X36 99 60802005 NUT ZINC COATED 6MA 100 61404122 FAN COLLECTOR BASE 101 60801093 SCREW 6X16 8 8 WITH WASHER UNI 6921 102 62111041 BAYONETTE SENSOR NTC 10K 2P MOLEX 103 62111042 BAYONETTE FUSE 203 F 2P MOLEX NON SST VENTING SEE SECTION 6 5 1 62111046 BAYONETTE FUSE 215 F 2P MOLEX SST VENTING SEE SECTION 6 5 1 104 60702083 OR...

Page 145: ...HAPTER 12 SPARE PARTS OMM 0100_0D AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 145 of 154 GF 146 Ph 800 526 0288 03 28 16 12 3 AM 750 1000 Spare Parts Drawings Figure 12 4 AM 750 1000 General Assembly Parts Drawing 1 of 2 ...

Page 146: ...and Water Heaters CHAPTER 12 SPARE PARTS Page 146 of 154 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0100_0D 03 28 16 Ph 800 526 0288 GF 146 Figure 12 5 AM 750 1000 General Assembly Parts Drawing 2 of 2 ...

Page 147: ...s and Water Heaters CHAPTER 12 SPARE PARTS OMM 0100_0D AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 147 of 154 GF 146 Ph 800 526 0288 03 28 16 Figure 12 6 AM 750 1000 Burner Fan Assembly Parts Drawing ...

Page 148: ...TOR 1 EXCHANGER 750 Models Only 15 61405316 D 125 H 809 COLLECTOR 2 EXCHANGERS 1000 Models Only 16 60702097 GASKET D 119 H 16 I 94 17 60702096 GASKET D 66 H 16 I 45 18 60502085 SINGLE GREY BOARD CLAMP 18 60502086 ON FLOOR YELLOW GREEN BOARD CLAMP 18 60502101 SINGLE BLUE BOARD CLAMP 19 60506031 BLACK 2 POLES SWITCH 20 60507059 CONNECTION BOARD 160X100 21 62113046 PRESSURE SWITCH ON 3 2 IN W C 22 62...

Page 149: ...4 2 WAY VALVE MOTOR Models WITH Motorized Valve 55 62621152 COPPER TUBE D28 F F 1 1 4 1 1 4 RIT Models WITH Motorized Valve 56 60801065 6X12MM TC CR SCREW 57 62113045 PRESSURE GAUGE BAR 58 60107005 PLUG BRASS 1 4P M WITH O RING 59 60801151 SCREW 4X10 GALVANIZED 60 61408014 BRASS CONNECTION 1 1 4 IN EXIT 61 62616111 KIT FOR 6 OR AND 3 WASHERS 62 61408013 BRASS CONNECTION 1 1 4 IN ENTRANCE 63 605100...

Page 150: ...rature bayonette fuse NOTE FOR UNITS WITH HIGH TEMPERATURE VENT KIT 69254 ONLY 98 60702083 OR RING 3137 EPDM 2 62 X 34 60 99 61405300 CONDENSATION DISCHARGE PIPE D 46 7 100 60801138 SCREW 4X8 ZINC TC CR DIN4042 101 60505028 IGNITION ELECTRODE 102 60701022 GASKET KERASIL 325R SQ 56X22X2 103 62632006 KIT THERMAL INSULATIONS 104 60701021 GASKET S WOLL PLUS D 100 SP 2 105 62629045 FIBER BURNER D 70 H2...

Page 151: ...ter part drawings and part lists Figure 12 7 AMR Piping and Parts Identification Partially Exploded 121700 1 99232 27 97082 25 26 97085 23 93513 17 93503 93512 22 92128 14 93505 19 93506 20 93501 16 91044 5 10 11 18 93504 30 63174 13 91044 36 00 28 99233 x3 35044 34 31 97084 31 25 97082 6 56085 x 6 54028 x5 35 93507 21 90046 3 36 90124 33 93563 32 93506 20 90124 33 93563 32 29 63173 93507 21 91044...

Page 152: ...1044 36 00 COPPER TUBE 2 x 36 00 LG 14 1 92128 FULL PORT BALL VALVE 3 4 NPT 15 1 92129 T P RELIEF VALVE 1 MNPT x 1 FNPT 16 1 93501 ELBOW 90 DEG SOCKET TO SOCKET 2 TUBE 17 1 93503 TEE SOCKET TO SOCKET 2 TUBE 18 1 93504 WYE STAINER 2 TUBE 19 1 93505 HEX REDUCING BUSHING 1 MNPT x 3 4 FNPT 20 2 93506 ELBOW 90 DEG 2 1 2 FNPT 21 2 93507 HEX REDUCING BUSHING 2 1 2 MNPT x 2 FNPT 22 1 93512 ADAPTOR 3 4 TUB...

Page 153: ...X A CONTROL PANEL OPERATION FLOW CHART OMM 0100_0D AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 153 of 154 GF 146 Ph 800 526 0288 03 28 16 APPENDIX A CONTROL PANEL OPERATION CHART Figure A 1 Flow Chart of Control Panel Operation ...

Page 154: ...ty Created introduction to AM models and AMR option in Functional Overview section and placed AMR function diagram at end Replaced all AMR figures separated Chapter 1 into five separate chapters created new AMR parts list and illustration added tank anode maintenance details and added to parts list and various misc changes Curtis Harvey 03 28 2016 Rev D Added SST venting down rate menu fuse change...

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Aerco AM 1000B, User Manual

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