Aerco GF-146-IR Installation, Operation, Maitenance Manual Download

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Installation, Operation, & Maintenance Manual (IOMM)

GF-146-IR

SUPPLEMENT TO

USER MANUAL GF-146

Integrated Rapid Recovery

Gas-Fired Water Heater Systems

AM 399R/500R

IMPORTANT NOTE!

This is a supplement and

MUST

be used in conjunction with the AM

Series main user manual,

GF-146

when installing gas, air, and vent

piping and when operating, and

maintaining AMR Integrated units.

Selectable Natural Gas or Propane
Modulating and Condensing
Water Heater with Integrated
Buffer Tank

This supplement pertains to the following

AMR Integrated water heater models:

Applies to all units with serial number of

15000000 and above.

Latest Update: 07/22/2015

•

AM 199R

•

AM 250R

•

AM 399R

•

AM 500R

PENDING

Page

AERCO International, Inc.

•

100 Oritani Dr.

•

Blauvelt, NY 10913

OMM-0106_0A

PRI - 07/22/15

Ph.: 800-526-0288

GF-146-IR

Summary of Contents for GF-146-IR

Page 1: ...and vent piping and when operating and maintaining AMR Integrated units Selectable Natural Gas or Propane Modulating and Condensing Water Heater with Integrated Buffer Tank This supplement pertains to the following AMR Integrated water heater models Applies to all units with serial number of 15000000 and above Latest Update 07 22 2015 AM 199R AM 250R AM 399R AM 500R PENDING Page 1 of 52 AERCO Inte...

Page 2: ...formation related to the surrounding contextual information and highlighted for special attention Cautions CAUTION CAUTION messages inform of potential problems relating to the functioning of equipment safety to persons harm to the environment and or damage to property or equipment Warnings WARNING WARNING messages warn of potential dangerous situations that may result in serious injury and or dea...

Page 3: ...D SUPPLY AND RETURN PIPING DIMENSIONS 18 CHAPTER 4 INSTALLATION PIPING 19 4 1 AMR INTEGRATED WATER CONNECTIONS 19 4 2 SAFETY RELIEF VALVE 19 4 3 RECIRCULATOR HEATING PUMP SIZING AND INSTALLATION 21 4 3 1 Recirculator Pump Sizing 21 4 3 2 Recirculation Pump Selection 21 4 3 3 Recirculator Pump Mechanical Installation 22 4 3 4 Recirculator Pump Electrical Connections 22 4 4 DOMESTIC HOT WATER SYSTEM...

Page 4: ...nts and Piping Maintenance 35 10 3 2 Buffer Tank Anode Rods 36 CHAPTER 11 TECHNICAL DATA 37 CHAPTER 12 SPARE PARTS DRAWINGS LISTS 38 12 1 AMR INTEGRATED SPARE PARTS DRAWINGS 38 12 2 199R 250R SPARE PARTS LIST 41 APPENDIX A CONTROL PANEL OPERATION CHART 49 APPENDIX B FACTORY MENU 50 STANDARD WARRANTY 51 STANDARD WARRANTY 52 Page 4 of 52 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0...

Page 5: ...omestic water heating plant up and running quickly Multiple units can be located with near zero side clearance for even larger installations The AMR Series also includes skid mounted units with selectable exterior mounted tanks and optional AERCO SR300 Scale Reducing Systems for information concerning skid mounted units The AMR ships ready to be piped into a domestic water heating system to provid...

Page 6: ...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 installation and maintenance sections of this manual are for use only by a qualiﬁed heating installer Refer to Chapter 9...

Page 7: ...erty 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 with the applicable local and or national regulations in force Incorrect use of this appliance Inadequat...

Page 8: ... Integrated Water Heaters Supplement to GF 146 CHAPTER 1 GENERAL INFORMATION OFF OFF Page 8 of 52 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0106_0A PRI 07 22 15 Ph 800 526 0288 GF 146 IR ...

Page 9: ...ations within the Commonwealth of Massachusetts must conform to the following requirements Water heater 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 using a non corrosive soap The vent termination must be located a minimum of 4 feet above grade level If ...

Page 10: ... feature one burner and an integrated tank and the 399R and 500R which feature two burners and an integrated tank The AM 399R 500R are shown in Figure 2 1 Figure 2 1 AMR Integrated water Heater with Front Covers Left and Without Covers and Open Panel Right AM 399R 500R Shown CONTROL PANEL TANK ANODE BURNER 2 SLAVE BURNER 1 MASTER CONDENSATE DRAINAGE SYSTEM FLUE EXHAUST CHIMNEY BUFFER TANK UPPER FR...

Page 11: ...ity of the system water is very important Poor water quality can damage the water heater due to scale formation and corrosion The heater must be connected to a domestic hot water supply with compatible speciﬁcations performance and power rating Functional diagrams for all models are shown in the following section 2 3 AMR Integrated Series Functional Schematics 2 3 1 AM 199R 250R Functional Schemat...

Page 12: ... GF 146 CHAPTER 2 FUNCTIONAL OVERVIEW 2 3 2 AM 399R 500R Functional Schematic Figure 2 3 AM 399R 500R Functional Schematic Page 12 of 52 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0106_0A PRI 07 22 15 Ph 800 526 0288 GF 146 IR ...

Page 13: ...stalled 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 sun and frost NEVER place this appliance in a location that would subject it to temperatures at or near f...

Page 14: ...to the heating system connection to the electrical supply disposal of the condensation produced by the water heater connection to the room thermostat building automation system or equivalent device piping of the safety relief valve discharge connection of the outdoor temperature sensor possible connection of an indirect water heater If ﬂooding is possible elevate the water heater sufﬁciently to pr...

Page 15: ...inimum required clearances for ease of access but larger service 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 m...

Page 16: ...ocations that can allow contamination of combustion 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 Transportation Requirements Only transport the unit using the correct transportation equipment such as a hand truck with a fastening belt or sp...

Page 17: ...ver plate C to access and remove the two screws D from the floor of the unit fastening the unit front to the pallet Replace all covers Figure 3 2 Removing the Front from Wood Pallet 3 Remove two screws E from the shipping brackets to remove unit from pallet rear Figure 3 3 Removing the Rear from Wood Pallet 4 Install the two factory supplied eyebolts F on the upper side of the unit and attach chai...

Page 18: ...ard connections and dimensions for AMR Integrated Series units are shown in Figure 3 6 ITEM CONNECTION ITEM SIZE Water Supply Connection 1 1 4 Water Return Connection 1 1 4 Air Intake Connection Models 199 250 3 Models 399 500 4 Flue Exhaust Connection Models 199 250 3 Models 399 500 4 Gas Connection 1 Condensate Hose Figure 3 6 AMR Integrated Installation Connection Dimensions 1 2 3 4 5 6 Page 18...

Page 19: ... 4 7 An Anti scald mixing valve is recommended when storing domestic hot water above 115 F An anti scald mixing valve MUST always be installed on an AMR system Unions Field supplied Install Unions as shown on Figures 4 5 and 4 7 recommended for unit serviceability Tank sensor Factory supplied on water heater The tank sensor MUST be installed in the lower 1 3 of the storage tank to achieve proper o...

Page 20: ... tank Ensure the expansion tank is properly sized for the boiler volume and the system volume temperature and pressure See figures 4 5 and 4 7 for suggested tank location SEPARATE PIPING TO POINT OF RELIEF FOR VALVE DISCHARGE DRAINAGE TEMPERATURE AND PRESSURE GAUGE TEMPERATURE AND PRESSURE GAUGE SAFETY RELIEF VALVE 2 FACTORY SUPPLIED SAFETY RELIEF VALVE 2 DISCHARGE PIPING FIELD SUPPLIED CONDENSATE...

Page 21: ...h a circulator pump for domestic potable hot water 4 5 1 Recirculator Pump Sizing The water resistance to size the recirculator pump to supply ﬂow through the heating system at the AMR Integral unit s connections is shown in graph form in Figure 4 2 It is up to the installer to ensure the minimum system ﬂow is not less than 4 GPM at any time If the ﬂow is lower the unit automatically stops the bur...

Page 22: ...ectrical junction box by removing screw at rear top of junction box cover and lifting up as shown in Figure 4 4 Figure 4 4 Recirculator Pump Wiring to AMR Electrical Power Terminals 2 Use a three conductor cable minimum cross section of 18 AWG and run out of the power box conduit opening and between the water heater terminals and the recirculation pump 3 Locate the left side set of 120 VAC power t...

Page 23: ...e 4 5 for recommended piping for AM Series water heater single unit installations and Figure 4 7 for multiple unit installations Refer to section 4 3 4 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 OMM 0106_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 23 of 52 GF 146 IR Ph 800 526...

Page 24: ...re 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 details the relationship of water temperature and time with regard to scald injury and may be used as a guide in determ...

Page 25: ...plement to GF 146 CHAPTER 5 INSTALLATION PIPING Figure 4 7 AMR Integrated Multi Unit Installation Piping Example OMM 0106_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 25 of 52 GF 146 IR Ph 800 526 0288 PRI 07 22 15 ...

Page 26: ...d empties into the floor drain or drain pan Figure 4 9 The condensation disposal system must slope the condensate tubing down and away from the water heater without any subsequent elevation into a drain or drain pan See Figure 4 9 Condensate from the water heater will be slightly acidic around pH 4 The neutralizing tank see Figure 4 8 item B is built into the water heater and will neutralize the c...

Page 27: ...When installing a condensate pump select one approved for use with condensing water heaters and furnaces The pump should have an overﬂow switch to prevent property damage from condensate spillage Floor Drain or Drain Pan NO YES Condensate Drain Pipe PROPER DRAIN HOSE ANGLE OMM 0106_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 27 of 52 GF 146 IR Ph 800 526 0288 PRI 07 22 15 ...

Page 28: ... install a fused disconnect or service 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 AMR Integrated Electrical Junction Box Connections Page 28 of 52 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0106_0A PRI 07 22 15 Ph 800 526 0288 GF 146 IR ...

Page 29: ...e Cascade Sequencer one must follow the electrical connections as per Figure 5 4 A maximum of eight heaters can be connected in a cascade Refer to the AERCO Cascade Sequencer user manual GF 146 CS for information on how to set up and use a cascade system using AM water heaters Figure 5 4 Cascading AM Units Electrical Connections OMM 0106_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 ...

Page 30: ...n 1 5V and 2 0V the heater start to operate and the supply temperature stays at the value set for the Minimum CH setpoint parameter 3018 in the Factory menu per Appendix B As the input voltage changes between 2V and 10V the supply temperature will change proportionally between the Minimum CH setpoint parameter 3018 in the Factory menu per Appendix B and the Maximum CH setpoint parameter 3017 in th...

Page 31: ...ns pertaining to the installation of the exhaust venting and combustion air piping for the AM series of units WARNING You MUST refer to and comply with all instructions warnings cautions notes and other information in the main AM Series user manual GF 146 pertaining to Chapter 6 to prevent a dangerous situation harm to persons and damage to equipment OMM 0106_0A AERCO International Inc 100 Oritani...

Page 32: ... to the installation of the natural gas inlet piping for the AM series of units WARNING You MUST refer to and comply with all instructions warnings cautions notes and other information in the main AM Series user manual GF 146 pertaining to Chapter 7 to prevent a dangerous situation harm to persons and damage to equipment Page 32 of 52 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 01...

Page 33: ...g to unit start up procedures for the AM series of units WARNING You MUST refer to and comply with all instructions warnings cautions notes and other information in the main AM Series user manual GF 146 pertaining to Chapter 8 to prevent a dangerous situation harm to persons and damage to equipment OMM 0106_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 33 of 52 GF 146 IR Ph 800 ...

Page 34: ...ng to unit operation of the AM series of units WARNING You MUST refer to and comply with all instructions warnings cautions notes and other information in the main AM Series user manual GF 146 pertaining to Chapter 9 to prevent a dangerous situation harm to persons and damage to equipment Page 34 of 52 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0106_0A PRI 07 22 15 Ph 800 526 028...

Page 35: ...l other maintenance procedures applicable to the all models of AM Series models CAUTION Servicing inspection and adjustment must be done by a trained technician in accordance with all applicable local and national codes Improper servicing or adjustment could damage the water heater and result in equipment damage or a dangerous condition 10 3 Maintenance Specific to AMR Integrated Water Heaters 10 ...

Page 36: ...eck the reduction in anode diameter Original anode rod diameter is 3 4 0 75 and anode should be replaced if diameter is reduced by 20 to 3 5 0 60 diameter or less Figure 10 14 shows a comparison of an old anode needing replacement and a new anode Contact AERCO Technical Support for replacement anodes NEW ANODE ROD 3 4 DIAMETER OLD ANODE ROD NEEDING REPLACEMENT DUE TO EXCESSIVE DIAMETER REDUCTION A...

Page 37: ...de with LP gas ppm 250 250 250 250 NOx 0 O2 with natural gas ppm 30 30 30 30 CO2 Carbon dioxide for Natural gas t hi h fi 8 4 to 8 7 8 8 to 9 1 8 4 to 8 7 8 8 to 9 1 CO2 Carbon dioxide for Natural gas t l fi 8 4 to 8 7 8 8 to 9 1 8 4 to 8 7 8 8 to 9 1 CO2 Carbon dioxide for LP gas at hi h fi 9 5 to 10 9 5 to 10 9 5 to 10 9 5 to 10 CO2 Carbon dioxide for LP gas at l fi 10 5 to 11 5 10 5 to 11 5 10 ...

Page 38: ... SPARE PARTS CHAPTER 12 SPARE PARTS DRAWINGS LISTS 12 1 AMR Integrated Spare Parts Drawings Figure 12 1 199R 250R Spare Parts Drawing 1 of 2 Page 38 of 52 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0106_0A PRI 07 22 15 Ph 800 526 0288 GF 146 IR ...

Page 39: ...Supplement to GF 146 CHAPTER 12 SPARE PARTS Figure 12 2 AMR Integrated General Assembly Parts drawing 2 of 2 OMM 0106_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 39 of 52 GF 146 IR Ph 800 526 0288 PRI 07 22 15 ...

Page 40: ... Supplement to GF 146 CHAPTER 12 SPARE PARTS Figure 12 3 199R 250R 399R 500R Burner Fan Spare Parts Drawing Page 40 of 52 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0106_0A PRI 07 22 15 Ph 800 526 0288 GF 146 IR ...

Page 41: ...ELAYED GLASS 19 60507059 CONNECTION BOARD 160X100 20 60503026 FUSE 3A DELAYED GLASS 21 62113046 PRESSURE SWITCH ON 3 2 INWC 22 60702097 GASKET D 119 H 18 I 94 23 60503064 RELAY 115V 16A EXCHANGE 24 62110071 SENSOR 10K D6X45 L 2500 T 25 62110067 OUTDOOR SENSOR 26 62417028 DOCUMENTS x2 AMR INTEGRATED WATER HEATER SUPPLEMENT GF 146IR AM SERIES USER MANUAL GF 146 REV D 27 62403631 28 62630184 29 62630...

Page 42: ...5 CROSS HEAD 65 60701008 1 1 2 GASKET 66 62621154 COPPER TUBE D28 F F 1 1 4 1 1 4 67 61212014 VORTEX FLOW SENSOR 68 62621187 COPPER TUBE D28 F F 1 1 4 1 1 4 NO VALV 69 60110048 BRASS NIPPLE 1 1 4 F 29 H 52 70 60101268 REDUCTION 1 1 4 1 1 2 F 31 71 62621204 RETURN PIPE BOILER PUMP 72 62621205 RETURN PIPE TANK PUMP 6 1 2 73 62621206 RETURN PIPE TANK PUMP 8 1 2 74 60110034 BRASS NIPPLE DOUBLE 1 1 2 7...

Page 43: ...100 SP 2 109 60703047 SIL GASKET D 200 F 188 H 7 2 110 60801014 SCREW 4X10 ZINC TC CR 111 60101224 FLANGE GAS 32X32 3 4P 112 60702029 O RING 130 2 62 X 22 22 113 60404253 FLANGE L21 2 H34 SP1 114 60815013 PIREX GLASS D15 5 SP5 115 60701013 GASKET FRIZITE D15 5 F11 5 SP1 5 116 62651054 HIGH POWER SILENCER GROUP 117 60702072 O RING 156 NBR 3 53 X 52 39 118 62632009 GRP SPARE GAS VALVE AIR 119 608011...

Page 44: ...Heaters Supplement to GF 146 CHAPTER 12 SPARE PARTS Figure 12 4 399R 500R Spare Parts Drawing 1 of 2 Page 44 of 52 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0106_0A PRI 07 22 15 Ph 800 526 0288 GF 146 IR ...

Page 45: ... 500R Spare Parts Drawing 1 of 2 NOTE See Figure 12 3 for the burner assembly part drawings as the parts and item numbers are identical for all models of AM series units OMM 0106_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 45 of 52 GF 146 IR Ph 800 526 0288 PRI 07 22 15 ...

Page 46: ...A DELAYED GLASS 21 62113046 PRESSURE SWITCH ON 3 2 INWC 22 60702097 GASKET D 119 H 18 I 94 23 60503064 RELAY 115V 16A EXCHANGE 24 62110071 SENSOR 10K D6X45 L 2500 T 25 62110067 OUTDOOR SENSOR 26 62417028 DOCUMENTS x2 AMR INTEGRATED WATER HEATER SUPPLEMENT GF 146IR AM SERIES USER MANUAL GF 146 REV D 27 62403631 28 62630184 29 62630185 29 62630192 LP TO NAT CONV KIT 250 500 750 1000 30 62801022 NEUT...

Page 47: ...8 62621187 COPPER TUBE D28 F F 1 1 4 1 1 4 NO VALV 69 60110048 BRASS NIPPLE 1 1 4 F 29 H 52 70 60101268 REDUCTION 1 1 4 1 1 2 F 31 71 62621203 RETURN PIPE HEATER PUMP 72 62621205 RETURN PIPE TANK PUMP 6 1 2 73 62621206 RETURN PIPE TANK PUMP 8 1 2 74 60110034 BRASS NIPPLE DOUBLE 1 1 2 75 62113045 PRESSURE GAUGE 0 10 BAR 76 60801151 SCREW 4X10 GALVANIZED 77 61408013 BRASS CONNECTION 1 1 4 RETURN 78 ...

Page 48: ...801014 SCREW 4X10 ZINC TC CR 111 60101224 FLANGE GAS 32X32 3 4P 112 60702029 O RING 130 2 62 X 22 22 113 60404253 FLANGE L21 2 H34 SP1 114 60815013 PIREX GLASS D15 5 SP5 115 60701013 GASKET FRIZITE D15 5 F11 5 SP1 5 116 62651054 HIGH POWER SILENCER GROUP 117 60702072 O RING 156 NBR3 53 X 52 39 118 62632009 GRP SPARE GAS VALVE AIR 119 60801159 SCREW 4X14 GALVANIZED 120 61404121 90 INTERNAL ELBOW 12...

Page 49: ...tructions pertaining to unit operation of the AM series of units WARNING You MUST refer to and comply with all instructions warnings cautions notes and other information in the main AM Series user manual GF 146 pertaining to Appendix A to prevent a dangerous situation harm to persons and damage to equipment OMM 0106_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 49 of 52 GF 146 I...

Page 50: ...to unit operation of the AM series of units WARNING You MUST refer to and comply with all instructions warnings cautions notes and other information in the main AM Series user manual GF 146 pertaining to Appendix B to prevent a dangerous situation harm to persons and damage to equipment Page 50 of 52 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0106_0A PRI 07 22 15 Ph 800 526 0288 ...

Page 51: ...er malfunction caused by defective installation or adverse local conditions specifically sediment or lime precipitate in the tank or corrosive elements in the atmosphere This warranty also does not cover misuse including lack of maintenance removal of magnesium anode s disconnection alteration or addition of non approved components or apparatus operation with fuels or at settings other than those ...

Page 52: ...rts not manufactured or sold by AERCO will void any warranty express or limited In order to process a warranty claim a formal purchase order number is required prior to shipment of any warranty item In addition the returned item must include a Returned Goods Authorization RGA label attached to the shipping carton which identifies the item s return address register number and factory authorized RGA...

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