Thermal Solutions AMP 1000 Installation, Operation And Maintenance Manual Download Page 82

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APPENDIX D

(continued)

Gas Selection Switch

High Gas Pressure Switch

Low Gas Pressure

Switch

Gas Valves

Low Gas Pressure

Switch

High Gas Pressure

Switch

LP/Propane Connection

Natural Gas Connection

Summary of Contents for AMP 1000

Page 1: ...TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the...

Page 2: ...A General Installation 15 B Appliance Mounting 16 C Clearances 17 D Clearances French 17 E Closet and Alcove installation 17 VII Venting 18 A General Venting Guidelines 18 B Venting Design Requirement...

Page 3: ...C Appliance Wiring 63 XIV System Start up 68 A Check System Setup 68 B Start the AMP 68 C Combustion Air Fuel Adjustment 70 D Field Conversion of Gas Type 71 E Pump Control 72 F Check Thermostat Opera...

Page 4: ...isdictional and professional codes and regulations I Hazard Definitions Indicatesanimminenthazardoussituationwhich ifnotavoided willresultindeath seriousinjuryorsubstantialpropertydamage Indicatesapot...

Page 5: ...ppliance 2 Failure to prevent the gas line from turning could damage the gas train components on the appliance gas valve blower etc E Appliance Operation 1 This appliance MUST NOT be installed in any...

Page 6: ...d 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 CSD 1 2 Insta...

Page 7: ...3500 4000 Fuel NG or LP NG or LP NG or LP NG or LP NG or LP NG or LP NG or LP NG or LP Max Water Temp F 1 210 210 210 210 210 210 210 210 Max Working Pres psi 160 160 160 160 160 160 160 160 Standard...

Page 8: ...8 52 5 8 52 5 8 52 5 8 M 44 3 8 44 3 8 44 3 8 44 3 8 57 3 4 57 3 4 57 3 4 57 3 4 N 2 1 8 2 1 8 2 1 8 2 1 8 2 1 8 2 1 8 2 1 8 2 1 8 O 9 3 4 9 3 4 9 3 4 9 3 4 9 3 4 9 3 4 9 3 4 9 3 4 P 13 3 8 13 3 8 13...

Page 9: ...ating Specifications and Dimensional Data continued G F Z COG X COG L J Z COG Y COG K M SUPPLY NOZZLE RETURN NOZZLE LIFTING LUGS Q T P S R O N 1 CONDENSATE DRAIN AIR SUPPLY VENT DRAIN A D E C I H B SU...

Page 10: ...ition The igniter assembly is installed on the burner door with two M4 x 10 screws 9 Flame observation port A inch diameter quartz sight glass provides a means of visual inspection of the burner flame...

Page 11: ...Refer to Table 2 for standard factory supplied relief valve sizes and optional sizes for all models 22 Condensate drain trap Serves to discharge condensate from the heat exchanger while preventing fl...

Page 12: ...12 IV AMP Component Identification continued Figure 2 Component Identification 1 4 19 16 3 15 12 5 15 6 13 11 21 13 14 20 10 9 8 17 19...

Page 13: ...13 IV AMP Component Identification continued Figure 3 Component Identification 26 25 22 18 2 23 27...

Page 14: ...shandled 11 Verify total number of pieces shown on packing slip with those actually received In case there is damage or a shortage immediately notify the carrier B Installation and Operation Manual 1...

Page 15: ...e must not be installed in a room under negative pressure An equipment room under negative pressure conditions could deplete the combustion air supply to the appliance and cause leakage of flue gas fr...

Page 16: ...edges of the appliance by at least 3 inches 76 2 mm in any direction This appliance shall never be installed directly on carpeted flooring a For closet or alcove installation the base shall cover the...

Page 17: ...3 Follow vent material manufacturer s instructions for vent clearances 4 Clearances for closet or alcove Installation Front 48 Sides 36 Rear 22 Top 20 Table 5 Clearances for Serviceability VI Pre Inst...

Page 18: ...ign Requirements At the 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...

Page 19: ...east 7 ft 2 1 m above a public walkway 10 Maintain minimum clearance of at least 4 ft 1 2 m 3 ft 900 mm in Canada horizontally between vent terminal and gas meters electric meters regulators and relie...

Page 20: ...tconnectorprovidesameans for vent connection 3 Vent and combustion air intake pipe must be supported to allow uniform flow of combustion air and flue gas 4 Plan venting system to avoid possible contac...

Page 21: ...imum ft m Pipe Dia in mm Minimum ft m Maximum ft m 1000 8 200 0 150 45 7 8 200 3 0 9 150 45 7 6 160 0 70 21 3 6 160 3 0 9 70 21 3 1250 8 200 0 150 45 7 8 200 3 0 9 150 45 7 6 160 0 50 15 2 6 160 3 0 9...

Page 22: ...nt Horizontal Sidewall Tee or straight 5 Intake Horizontal Sidewall Tee Vent Vertical Roof Tee or straight 6 Intake Vertical Roof Tee or 2 elbows Figure 9 Vent Vertical Roof Tee or straight Two Pipe C...

Page 23: ...tion of natural gas Table 10 Combustion Air and Flue Gas Flow Rates Table 11 Approved Vent Manufacturers and Materials Make Material Model Heat Fab Stainless Steel Saf T Vent EZ Seal Z Flex Nova Flex...

Page 24: ...2SVSTPX08 2500 3000 10 Tee 91090TEE 2SVST10 Elbow 91014TERM 2SVEE1090 Straight 91092 2SVSTPX10 3500 4000 12 Tee 91290TEE 2SVST12 Elbow 91214TERM 2SVEE1290 Straight 91292 2SVSTPX12 Table 13 Stainless S...

Page 25: ...25 VII Venting continued Figure 5 Direct Vent Terminal Clearances Figure 6 Other than Direct Vent Terminal Clearances...

Page 26: ...ator vent outlet to a maximum vertical distance of 15 ft 4 5 m J Clearance to nonmechanical air supply inlet to building or the combustion air inlet to any other appliance 6 in 15 cm for appliances 10...

Page 27: ...tor vent outlet to a maximum vertical distance of 15 ft 4 5 m J Clearance to nonmechanical air supply inlet to building or the combustion air inlet to any other appliance 6 in 15 cm for appliances 10...

Page 28: ...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 whic...

Page 29: ...m MIN VENT TERMINAL Figure 8 Horizontal Sidewall Termination Figure 9 Vertical Roof Termination VENT TERMINAL STORM COLLAR FLASHING BRACE IF REQUIRED Vent pipe minimum clearance to combustible materia...

Page 30: ...Guidelines for Horizontal sidewall terminations are shown in Figure 8 5 Guidelines for vertical roof terminations are shown in Figure 9 6 Adhere to the minimum and maximum wall thickness specified by...

Page 31: ...polypropylene liner is 48 ft 14 6 m WARNING WARNING Asphyxiation Hazard Vent systems made by listed PP vent system manufacturers rely on gaskets for proper sealing When this type of vent system is us...

Page 32: ...age Do NOT connect venting to a chimney flue that is servicing a separate appliance designed to burn solid fuel Do not insulate polypropylene vent pipes Excessive heat could cause premature vent pipe...

Page 33: ...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 total input rating...

Page 34: ...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 12 Multiple Appliance Direct Ven...

Page 35: ...3 Insofar as is practical close all exterior doors and windows and all doors between the space where the appliances connect to the common venting system and other spaces of the building Turn on any e...

Page 36: ...fication plate shall be permanently mounted to the exterior of the building at a minimum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented...

Page 37: ...sizing condensate drain line pump and neutralizer kit AMP Model Maximum Condensate Flow Rate GPH 1000 9 00 1250 10 32 1500 12 24 2000 16 10 2500 18 25 3000 21 40 3500 23 10 4000 24 00 Table 18 Maximum...

Page 38: ...condensate and lose neutralizing effectiveness over time Therefore periodic condensate neutralizer maintenance and limestonechip replacementarerequired forproper neutralization of the condensate AMP...

Page 39: ...spraying rain etc during appliance operation and service circulator replacement etc Oxygen contamination of the boiler water will cause corrosion of iron and steel boiler components and can lead to bo...

Page 40: ...0 400 50 150 250 350 6 7 13 35 10 20 16 7 0 100 3 35 Water Flow Rate gal min 2000 MBtu h 3000 MBtu h 4000 MBtu h 1500 MBtu h 1250 MBtu h Figure 15 Heat exchanger water pressure loss Recommended Range...

Page 41: ...Also when replacing the safety relief valve verify the temperature and pressure gauge meets ASME requirements for the replacement safety relief valve c Pipe the safety relief valve discharge to a loca...

Page 42: ...r with a hardness of less than 80 ppm 5 gpg can have a pH level that is corrosive c The pH of the water must be greater than 7 5 and less than 9 5 If the system contains aluminum parts the pH must be...

Page 43: ...epaired immediately DO NOT connect the boiler to radiant tubing without an oxygen barrier 3 There are many possible causes of oxygen contamination such as a Addition of excessive make up water as a re...

Page 44: ...11 X100 X500 Sotin 212 MC1 Noise reducer X200 Universal Cleaner Restorer X300 Sludge remover Protector F1 Cleaner F3 X400 Sotin 212 Antifreeze Alphi 11 X500 Tightness Leak Sealer F4 Treatment Type Pre...

Page 45: ...stem Circulator To System Isolation Valve Make Up Water Pressure Reducing Valve Purge Valve Air Vent Isolation Valve From System Boiler Circulator Check Valve Y Strainer Expansion Tank Single AMP BFIT...

Page 46: ...e the pressure drop across the entire loop A B From System To System Purge Valve System Circulator Air Vent Expansion Tank Pressure Reducing Valve Check Valve Factory Supplied Manifold Boiler Circulat...

Page 47: ...al requirements 2 Pressure relief valve rating shall not exceed pressure rating of any component in the system 3 Some piping components cannot be supported by the pipping Refer to the manufactures ins...

Page 48: ...essure relief valve rating shall not exceed pressure rating of any component in the system 3 Some piping components cannot be supported by the pipping Refer to the manufactures installation instructio...

Page 49: ...nd service circulatory replacement cleaning etc Contaminationofthewaterbycorrosivechemicals will cause corrosion of the steel components and can lead to appliance failure Thermal Solutions Standard Wa...

Page 50: ...rain it must terminate at least 6 in 150mm above the floor Do not run safety relief valve discharge pipe through an area prone to freezing The termination of discharge piping must be in an area where...

Page 51: ...corrosive to stainless steel Ensure the level of chlorine 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 4 Before...

Page 52: ...2000 196 20 1 157 14 2 131 10 6 112 8 4 98 6 8 87 5 6 78 4 8 71 4 1 2500 245 15 7 196 11 5 163 9 140 7 3 123 6 2 109 5 3 98 4 6 89 4 1 3000 294 20 3 235 14 8 196 11 5 168 9 3 147 7 8 131 6 7 118 5 8 1...

Page 53: ...ilure to adjust the flow rate to the specified values or use the appropriate pipe size can cause non warrantable damage 2 The wetted materials of the pump must be suitable for potable water Look for b...

Page 54: ...Water Return Factory Supplied Manifold Check Valve Water Heater Circulator Y Strainer Isolation Valve Storage Tank Thermometer Mixing Valve Cold Water Supply Hot Water Supply Exansion Tank T P Relief...

Page 55: ...rating of any components in the system 3 The circulator shall be sized to overcome the pressure drop across the entire loop 5 28 2 P BFIT 1 Heater 1 Tank 2 Temperature Piping NOTICE NOTICE 1 These are...

Page 56: ...tem Circulator Cold Water Supply Check Valve Expansion Tank Thermometer Hot Water Supply Storage Tank Mixing Valve Factory Supplied Manifold Water Heater Circulator Y Strainer Isolation Valve T P Reli...

Page 57: ...Heater Circulator T P Relief Valve System Circulator Recirculation Filter Mixing Valve Thermal Solutions Prod Notes 1 This is a suggested piping configuration It is the installer s responsibility to...

Page 58: ...Tanks Required Common Piping Sizes for Multiple Appliances AMPW Model Number of Appliances 2 3 4 5 6 1000 5 6 8 8 10 1250 5 6 8 8 10 1500 6 6 8 8 10 2000 6 8 10 10 10 2500 8 10 10 12 12 3000 8 10 10...

Page 59: ...al gas train connections 7 All threaded joints should be coated with piping compoundresistanttoactionofliquefiedpetroleum gas 8 The appliance and its gas connection must be leak tested before placing...

Page 60: ...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 4 0 9 0 4 0...

Page 61: ...liancemay result in improper operation and damage Always assure gas piping is absolutely leak free and of the proper size and type for the connected load An additional gas pressure regulator may be ne...

Page 62: ...One example of an external power source that could be inadvertently connected to the low voltage connections is a transformer with old thermostat wiring To obtain total system power consumption add al...

Page 63: ...ensor in areas where it may be covered with ice or snow Locations where the senor will pick up direct radiation from the sun should also be avoided c Avoid placing senors near potential sources of ele...

Page 64: ...J12 P4a 1 R2 R1 PCB 05 39 40 41 42 P2 2 P3 2 96 97 95 J7 99 100 98 102 103 101 91 90 P3 7 A4 J7 5 J5 Spare Limit J8 J9 J10 104 82 81 84 83 86 85 25 26 24 28 29 27 31 30 23 P2 5 P2 4 P3 1 J4 77 78 76 7...

Page 65: ...P3 1 J4 77 78 76 73 J2 75 74 J1 L1 J5 2 107 108 P3 3 109 110 Ground Screw Terminal P3 11 P1 3 P1 6 P2 1 P2 6 C C C NO NC NO NC C N A N A N A 1 2 3 1 2 3 Back View E 1 2 P1 P2 LT To Grounding Conductor...

Page 66: ...A B Cg 64 RJ45 P27 4 P27 5 6 1 Central Heat Enable Disable Input STAT F2 3A Slow Blow PCB 01 24Vdc Display Power Supply PCB 05 N A P5 5 N A Setpoint or Modulation 4 20mAdc Input Supplied by others J8...

Page 67: ...120 or 24 VAC N H F4 6 3A Slow Blow Wiring Legend Wiring Line Types Terminal Types Terminals C Common NC Normally Closed NO Normally Open Factory Wire Harness Line Voltage Factory Wire Harness Low Vo...

Page 68: ...pts contact factory or a qualified heating service technician 4 Begin commissioning the appliance Visually inspect flame via sight glass window On high fire the flame should be stable and mostly blue...

Page 69: ...es 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 est muni d un...

Page 70: ...s than 200 ppm 2 For low fire adjustment a Lock appliance in low fire and allow fan speed and combustion analyzer reading to stabilize before taking combustion readings To lock in low fire select High...

Page 71: ...Z223 1 NFPA 54 and or Natural Gas and Propane Installation Code CAN CSA B149 1 or the requirements of the authority having jurisdiction 2 Adjust the throttle screw towards negative all the way to the...

Page 72: ...t 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 hold the LWCO test b...

Page 73: ...l 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 with soap and...

Page 74: ...o the model size to witch it is installed WARNING WARNING Read and understand the entire manual before attempting installation start up operation or service Installation and service must be performed...

Page 75: ...ntains components that become very hot when the operating Do not touch any components unless they are cool This appliance contains materials of construction products of combustion and the fuel contain...

Page 76: ...lint and debris Replace burner if the surface shows any signs of damage due to improper handling or gas valve combustion settings f Do not use acid or alkali products or metallic brush to clean the h...

Page 77: ...ace filter if it appears damaged or deteriorated c Reinstall air filter and intake pipe 8 Insulations and gaskets a Visually inspect the following gaskets flue outlet blower burner and burner door D R...

Page 78: ...Other than Direct Vent Terminal Clearances 27 VIII Condensate Disposal 37 Table 18 Maximum Condensate Flow 37 Table 19 Condensate Neutralizer Kit 38 IX Hydronic Piping 39 Table 20 Temperature rise flo...

Page 79: ...ng diagrams 45 Figure 16 Single Boiler Primary Secondary Piping 45 Figure 17 Multiple Boiler Primary Secondary with Common Header Piping 46 Figure 18 Multiple Boiler Primary Reverse Return Piping 47 F...

Page 80: ...1 6200 7600 4600 4800 4500 5500 6200 6400 Minimum Modulation Rate RPM 1725 2000 1250 1350 1250 1400 1600 1700 Light off RPM 1 2400 2400 1900 1900 1900 2400 2400 2400 Maximum Light off RPM 2500 2500 20...

Page 81: ...n pressure rises above the setpoint Each gas train has one high gas pressure switch 5 Low Gas Pressure Switches a The low gas pressure switches monitor the supply gas pressure and shut off the electri...

Page 82: ...82 APPENDIX D continued Gas Selection Switch High Gas Pressure Switch Low Gas Pressure Switch Gas Valves Low Gas Pressure Switch High Gas Pressure Switch LP Propane Connection Natural Gas Connection...

Page 83: ...C C NO NC NO NC C N A N A N A 1 2 3 1 2 3 Back View E 1 2 P1 P2 LT To Grounding Conductor Boiler must be grounded in accordance with ANSI National Electric Code S T 1 N 105 106 P3 4 N A PCB 02 A B 1 1...

Page 84: ...A N A N A 1 2 3 1 2 3 Back View E 1 2 P1 P2 LT To Grounding Conductor Boiler must be grounded in accordance with ANSI National Electric Code 105 106 P3 4 N A A B 1 1 1 NO C 93 94 Transformer 120 24Va...

Page 85: ...85 Notes...

Page 86: ...86 This page is intentionally left blank...

Page 87: ...d only to the original owner at the original place of installation within the United States and Canada These warranties are applicable only to boilers parts or accessories designated as commercial gra...

Page 88: ...Thermal Solutions Product LLC Lancaster PA 17604 3244 Phone 717 239 7642 orders thermalsolutions com www thermalsolutions com...

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