AMP AMPW 1000 Installation, Operation And Maintenance Manual Download Page 65

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AMPW 400-1000L I&O Manual

D. Restarting after Prolong Shutdown

After prolonged shutdown, it is recommended that

the steps in "System Start-up"

and

"Service and

Maintenance" in this manual be performed.

E. Troubleshooting

Refer to the troubleshooting section in the Concert

Control manual on how to navigate the Limit String

Status screen which shows an active safety limit status

and for an in-depth guide to all the possible lockouts

as well as recommended corrective actions to restore

operation.

XIV

. Service and Maintenance

(continued)

Figure 32: Burner Door Opening

6 X M10

screws

Summary of Contents for AMPW 1000

Page 1: ...service must be performed by a qualified installer service agency or the gas supplier WARNING If the information in these instructions is not followed exactly a fire or explosion may result causing pr...

Page 2: ...nstallation and Mounting 13 A General 13 B Appliance Mounting 14 C Outdoor Installation 14 D AMP 400 1000L Stacking 15 E Clearances 16 F Clearances French 16 G Closet and Alcove Installation 16 H Side...

Page 3: ...equirements 50 C Appliance Wiring 50 D Routing Field Connections 50 E System and Circulation Pump Wiring 51 XIII System Start up 56 A Check System Setup 56 B Start the AMP 56 C Combustion Air Fuel Adj...

Page 4: ...dictional and professional codes and regulations I Hazard Definitions Indicates an imminent hazardous situation which if not avoided will result in death serious injury or substantial property damage...

Page 5: ...packing slip with received parts D Connecting Gas Supply Line 1 Connect supply gas line to the appliance gas train at the rear of the appliance 2 Failure to prevent the gas line from turning could da...

Page 6: ...atural Gas and Propane Code Where required by the authority having jurisdiction the installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME...

Page 7: ...P Max Water Temp F 1 210 210 210 210 210 Max Working Pres psi 160 160 160 160 160 Standard Safety Relief Valve psi 150 150 150 150 150 Water Vol gal 3 8 4 3 5 6 6 6 8 1 Heat Transfer Area sq ft 34 8 3...

Page 8: ...nsional Data continued 38 1 2 45 33 1 2 25 5 8 26 3 8 Front View 1 7 8 36 1 2 5 8 5 1 2 1 7 8 46 1 4 2 1 2 Side View 4 1 8 9 1 4 5 7 8 12 1 4 19 3 4 10 26 1 2 27 3 4 35 1 8 9 7 8 6 1 4 2 7 8 Rear View...

Page 9: ...oduct Rating Specifications and Dimensional Data continued 45 38 1 2 33 1 2 25 5 8 26 3 8 Front View 1 7 8 5 8 52 3 8 7 1 8 1 7 8 60 3 4 Side View 9 1 4 10 5 7 8 12 1 4 35 1 8 9 7 8 6 1 4 27 3 4 26 1...

Page 10: ...ater flow See Table21forminimumandmaximumwaterflowrates 15 Gas supply connection Connection to appliance gas train See Table 28 for model specific pipe sizes 16 Inlet Cold water connection 2 Male NPT...

Page 11: ...AMPW 400 1000L I O Manual 11 IV AMP Water Heater Component Identification continued 1 21 20 14 2 3 6 11 12 22 25 27 10 5 1 17 18 13 16 15 20 23 4 15 26 Figure 3 Component Identification...

Page 12: ...d on the appliance before operation a Loose shipping parts include Manual gas shutoff valve relief valve temperature and pressure gage and outlet water piping as shown in Figure 16 C Installation and...

Page 13: ...ontaining saw dust loose insulation fibers dry wall dust etc 6 This appliance must not be installed in a room under negative pressure An equipment room under negative pressure conditions could deplete...

Page 14: ...chloride used for water softening Refrigerant leaks Paint or varnish removers Hydrochloric acid muriatic acid Cements and glues Anti static fabric softeners used in clothes dryers Chlorine type bleach...

Page 15: ...appliance b Use the included screws to secure the brackets as shown in Figure 5 Figure 5 AMP 400 1000L Stacking Brackets and Dislplay Rotation 3 Outdoor AMP models cannot be stacked 4 The display bra...

Page 16: ...nstallation and Mounting continued NOTICE NOTICE This appliance is approved for zero inch clearance to combustible or noncombustible material but installing the appliance with smaller than the clearan...

Page 17: ...discretion of the installing contractor the venting system can be designed by consulting with approved venting engineers or by using the equivalent length method in this manual 1 Engineered Venting Me...

Page 18: ...nder decks or similar structures 12 Top of terminal must be at least 24 in 600 mm below ventilated eaves soffits and other overhangs In no case may the overhang exceed 48 in 1200 mm Where permitted by...

Page 19: ...Size and cut wall opening such that a minimal clearance is obtained and to allow easy insertion of vent pipe VII Venting continued E Venting for Outdoor Installation 1 The outdoor AMP ships from the f...

Page 20: ...nnot exceed maximum equivalent length shown in Table 6 2 Combustion air and vent terminations do not count towards total equivalent length AMP Model Combustion Air Length Vent Length Pipe Dia in mm Mi...

Page 21: ...dewall Tee or straight 8 Intake Horizontal Sidewall Tee or elbow Vent Vertical Roof Tee or straight 9 Intake Vertical Roof Tee or 2 elbows Figure 11 Vent Vertical Roof Tee or straight Room air for com...

Page 22: ...VC Adapting to Z DENS requires 4 increaser 2ZDI44 or 6 adapter 2ZDCPVCG6 Adapting to InnoFlue requires 4 adapter ISAAL0404 or 6 adapter ISAAL0606 Table 12 Stainless Steel Vent Terminations AMP Model V...

Page 23: ...AMPW 400 1000L I O Manual 23 VII Venting continued Figure 8 Vent Terminal Clearances...

Page 24: ...12 in 30 cm for appliances 10 000 Btuh 3 kW and 100 000 Btuh 30 kW 36 in 91 cm for appliances 100 000 Btuh 30 kW 6 in 15 cm for appliances 10 000 Btuh 3 kW 9 in 23 cm for appliances 10 000 Btuh 3 kW...

Page 25: ...3 kW 12 in 30 cm for appliances 10 000 Btuh 3 kW and 100 000 Btuh 30 kW 36 in 91 cm for appliances 100 000 Btuh 30 kW 4 ft 1 2 m below or to side of opening 1 ft 300 mm above opening K Clearance to a...

Page 26: ...ent pipe Exterior run to be included in equivalent vent combustion air lengths Vertical Venting and combustion air roof penetrations where applicable require the use of roof flashing and storm collar...

Page 27: ...12in 305mm MIN ABOVE COMBUSTION AIR TERMINAL 24 in 610mm MIN VENT TERMINAL VENT TERMINAL STORM COLLAR FLASHING BRACE IF REQUIRED Vent pipe minimum clearance to combustible material is 1in 25mm combust...

Page 28: ...3 mm mesh 4 Guidelines for Horizontal sidewall terminations are shown in Figure 10 5 Guidelines for vertical roof terminations are shown in Figure 11 6 Adhere to the minimum and maximum wall thickness...

Page 29: ...pipe Multiply measured flexible polypropylene liner length by 1 2 to obtain equivalent length 3 Maximum equivalent vent length of flexible polypropylene liner is 48 ft 14 6 m WARNING WARNING Asphyxiat...

Page 30: ...property damage Do NOT connect venting to a chim ney flue that is servicing a separate appliance designed to burn solid fuel Do not insulate polypropylene vent pipes Excessive heat could cause premat...

Page 31: ...g shall be 1 in 2 4000 Btu hr 550 mm2 kW of total input rating of all appliances within the enclosure ii Horizontal ducts minimum free area of each opening shall be 1 in 2 2000 Btu hr 1100 mm2 kW of t...

Page 32: ...plus the expected snow accumulation e Multiple individual vertical vent pipes may be piped through a common conduit or chase so that one roof penetration may be made Figure 14 Multiple Appliance Direc...

Page 33: ...ce being inspected Follow the Lighting or Operating Instructions Adjust thermo stat so appliance will operate continuously 5 Test for spillage at the draft hood relief opening after 5 minutes of main...

Page 34: ...nbythestateorlocalgasinspector of the sidewall horizontally vented equipment shall not be performed until proof is provided that the state or local electrical inspector having jurisdiction has granted...

Page 35: ...r condensate piping c Do not route or terminate the condensate drain line in areas subject to freezing temperatures Figure 15 Condensate Drain Assembly NOTICE NOTICE Do not crimp condensate drain line...

Page 36: ...veness over time Therefore periodic condensate neutralizer maintenance and limestone chip replacement are required for proper neutralization of the condensate C Common Condensate pump Sump 1 A common...

Page 37: ...ped to the primary loop going into the appliance 6 Circulation pump must be installed in the primary piping between the tank and the water heater NOTICE NOTICE Failure to properly pipe appliance may r...

Page 38: ...16 Item no Description 1 2 X 2 X 1 2 reducing tee 2 2 pipe nipple close 3 2 X 2 X 3 4 reducing tee 4 3 4 pipe nipple close 5 3 4 X 1 2 reducing tee 6 T P relief valve 7 1 2 pipe nipple x 1 1 2 Long 8...

Page 39: ...andard for relief valves for hot water supply systems ANSI Z21 22 CSA 4 4 Must be field installed as shown in Figure 16 b The safety relief valve must be installed with the spindle in a vertical posit...

Page 40: ...P heat exchanger is made from stainless steel tubular double coil having relatively nar row waterways Once filled with water it will be subject to the effects of corrosion Failure to take the followin...

Page 41: ...e is less than 5 ppm and the level of chloride is less than 1000 ppm a The AMP is not designed for the heating of swimming pool water 6 Before connecting the appliance insure the system is free of imp...

Page 42: ...e 1 This water heater has a temperature rise delta limit of 55 F Figure 17 Heat exchanger water pressure loss IX Water Piping continued F Temperature Rise and Heat Exchanger Head Loss 1 The AMP heat e...

Page 43: ...n the tubes of the heat exchanger or the primary piping Failure to adjust the flow rate to the specified values or use the appropriate pipe size can cause non warrantable damage 2 The wetted materials...

Page 44: ...component in the system 3 Some piping components cannot be supported by the pipping Refer to the manufactures installation instructions 4 Circulation pump must be sized to overcome the pressure drop a...

Page 45: ...ported by the pipping Refer to the manufactures installation instructions 4 Circulation pump must be sized to overcome the pressure drop across the entire loop 5 Erosion could occur if common piping i...

Page 46: ...lief Valve Isolation Valve Union Y Strainer Isolation Valve Water Heater Circulator Storage Tank Check Valve Union X Water Piping Diagrams continued NOTICE NOTICE 1 These are suggested piping configur...

Page 47: ...t be leak tested before placing it in operation 7 To protect the gas valve when testing over 1 2 psig 3 4 kPa the appliance and its individual shutoff valve must be disconnected from gas supply piping...

Page 48: ...4 17 3 8 7 4 3 0 7 1 6 3 5 1 6 3 1 0 824 0 5 22 9 11 4 5 7 1 0 2 1 4 6 2 1 4 1 1 1 049 0 6 29 1 14 6 7 3 1 2 2 6 5 8 2 6 5 2 1 1 38 0 8 38 3 19 1 9 6 1 6 3 5 7 7 3 5 6 9 1 1 61 0 9 44 7 22 4 11 2 1 9...

Page 49: ...Failure to use proper thread compounds on all gas connections may result in leaks of flammable gas Gas supply to appliance and system must be com pletely shut off prior to installing or servicing the...

Page 50: ...epresent the appliance s maximum power consumption AMP Model Voltage Phase Hz Appliance Amperage 400 120 1 60 7 500 7 650 8 800 8 1000L 8 Table 29 Electrical Ratings DANGER DANGER Electrical Shock Haz...

Page 51: ...ng a 2 conductor UL Type CM AWM Style 2092 300 Volt 60 C shielded E System and Circulation Pump Wiring 1 The system pump can be wired to System Pump on the 120 VAC PCB 2 The primary Tank circulation p...

Page 52: ...SOR OPTIONAL DOMESTIC HOT WATER SENSOR OPTIONAL MULTIPLE APPLIANCE COMMUNICATION OPTIONAL ENERGY MANAGEMENT SYSTEM OR SPACE HEATING THERMOSTAT OPTIONAL DOMESTIC HOT WATER THERMOSTAT IF USED ON OFF SWI...

Page 53: ...ND HIGH LIMIT AS SHOWN 4 DO NOT EXCEED 5 6A TOTAL PUMP CURRENT DRAW PRIMARY PUMP SYSTEM PUMP DHW PUMP COMBUSTION AIR DAMPER FOR PUMPS WITH AMPRATINGS GREATER THAN 5 6A USE RELAY OR STARTER COIL CONNEC...

Page 54: ...E 1 Control R7910 Spark J6 2 J8 1 J6 1 J6 3 J2 1 J2 2 J2 3 J2 4 J6 7 J6 8 J3 7 D J3 8 R J3 9 C Modbus 1 J3 1 A J3 2 B P10 9 P10 5 P10 10 MODBUS Communication EMS COM 1 A COM 6 B Host USB COM 4 A COM 9...

Page 55: ...ta DOP Display V G V 24VDC Display Power Supply Flue Gas Sensor Outlet Supply Sensor Inlet Return Sensor Combustion Fan DC Conn 1 DC 2 Tach 3 N C 4 PWM 5 DC Burner Thermal Fuse with manual reset P8 13...

Page 56: ...e Concert Control is required to restart If ignition is not achieved in three consecutive attempts contact factory or a qualified heating service technician DANGER DANGER Do not use matches candles or...

Page 57: ...s la lettre les instructions dans la pr sente notice risque de d clencher un incendie ou une explosion entra nant des dommages des blessures ou la mort A Cet appareil ne comporte pas de veilleuse Il e...

Page 58: ...xternal limits or other controls in accordance with the manufacturer s instructions 6 Verify O2 or CO2 and CO concentration are within limits specified in Table 30 Note the values in this table are fo...

Page 59: ...being converted a Gas conversion kits include a mixer and label See Table 32 for part numbers b Replace the old mixer with the new one 2 Connect the new gas supply to the appliance check for leaks and...

Page 60: ...he power Re connect wire to the blocked condensate switch Reset the blocked condensate switch lockout Hard Lockout Blocked Condensate switch Low Water Cutoff While the appliance is running push and ho...

Page 61: ...Occupational Safety and Health NIOSH approved respirator 2 Long sleeved loose fitting clothing 3 Gloves 4 Eye Protection Take steps to assure adequate ventilation Wash all exposed body area gently wi...

Page 62: ...servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing A General Maintenance 1 Keep the area around the appliance free from combustible mat...

Page 63: ...esent in theairaroundtheappliance Nevermodify remove or tamper with any control device WARNING WARNING This appliance contains components that become very hot when the operating Do not touch any compo...

Page 64: ...r firstremovefrontjacketpanelandthendisconnect the gas train assembly at the union connection and the mixer connection b Remove the filter box from the mixer c Removeallsixboltsusedtofastentheburnerdo...

Page 65: ...erformed E Troubleshooting Refer to the troubleshooting section in the ConcertTM Control manual on how to navigate the Limit String Status screen which shows an active safety limit status and for an i...

Page 66: ...13 Polypropylene Vent Terminations 22 Table 14 Direct Vent Terminal Clearances 24 Table 15 Other than Direct Vent Terminal Clearances 25 VIII Condensate Disposal 35 Table 16 Condensate Neutralizer Ki...

Page 67: ...te Combustion Air Intake 30 Figure 14 Multiple Appliance Direct Vent Termination 32 VIII Condensate Disposal 35 Figure 15 Condensate Drain Assembly 35 IX Water Piping 37 Figure 16 Hot Water Outlet Man...

Page 68: ...CH DHW Max Modulation Rate RPM 1 8000 8000 5550 5700 6400 6400 6800 Minimum Modulation Rate RPM 1600 1050 1100 1200 1200 1300 Light off RPM 1 3400 2400 2000 2400 1900 2400 Maximum Light off RPM 3600 2...

Page 69: ...AMPW 400 1000L I O Manual 69 Notes...

Page 70: ...70 AMPW 400 1000L I O Manual This page is intentionally left blank...

Page 71: ...mited warranties set forth above are extended only to the original owner at the original place of installation within the United States and Canada These warranties are applicable only to water heaters...

Page 72: ...Thermal Solutions Product LLC Lancaster PA 17604 3244 Phone 717 239 7642 orders thermalsolutions com www thermalsolutions com...

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