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Watts Aerco TAG-0072 GF-146-E, Operation & Maintenance Manual

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AM Series Boilers and Water Heaters User Manual

CHAPTER 10

– MAINTENANCE

OMM-0100_E

•

GF-146

•

11/15/2019

Technical Support

•

(800) 526-0288

•

Mon-Fri, 8 am - 5 pm EST Page 148 of 170

WARNING

Label all wires prior to disconnection when servicing controls. Wiring errors can cause
improper and dangerous operation! Verify proper operation after servicing. Failure to comply
with this warning can cause extensive property damage, severe personal injury or death!

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Summary of Contents for Aerco TAG-0072 GF-146-E

Page 1: ...ring in this manual not for incidental or consequential damages occurring in connection with the furnishing performance or use of these materials Operation Maintenance Manual AM Series Natural Gas and...

Page 2: ...ON 3 INSTALLATION SITE 29 3 1 CHOOSING THE INSTALLATION LOCATION 29 3 2 BOILER AND WATER HEATER INSTALLATION LOCATION FACTORS 30 3 3 SAFETY CONCERNS 31 3 4 CLOSET AND ALCOVE INSTALLATION 31 3 5 CLEARA...

Page 3: ...ers 62 5 4 AMR RAPID RECOVERY OPTION WIRING 62 SECTION 6 INSTALLATION VENTING AND COMBUSTION AIR PIPING 65 6 1 COMBUSTION AIR CONTAMINATION PREVENTION 65 6 2 GENERAL VENTING AND AIR PIPING SYSTEMS 66...

Page 4: ...as Type Conversion 95 8 3 IDENTIFICATION OF CONTROLS 96 8 4 BOILER STARTUP PROCEDURE 96 8 5 WATER HEATER STARTUP PROCEDURE 97 8 6 GAS SUPPLY PRESSURE TEST 98 8 7 COMBUSTION CALIBRATION 100 8 8 LOST IG...

Page 5: ...GAS SIDE 129 10 16 INSPECTING AND REPLACING THE HEAT EXCHANGER THERMAL INSULATION 133 10 17 INSPECTING AND REPLACING THE BURNER THERMAL INSULATION 134 10 18 CHECKING FOR GAS LEAKS AFTER REASSEMBLY 13...

Page 6: ...ly 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 equ...

Page 7: ...akdown 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 Quali ed installer using original spare parts Failure to...

Page 8: ...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...

Page 9: ...AM Series Boiler Water Heater User Manual CHAPTER 1 GENERAL INFORMATION OMM 0100_E GF 146 11 15 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 9 of 170 OFF OFF...

Page 10: ...g 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 Boile...

Page 11: ...s are appended 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...

Page 12: ...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...

Page 13: ...FUNCTIONAL OVERVIEW OMM 0100_E GF 146 11 15 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 13 of 170 2 5 AM Series Functional Schematics 2 5 1 AM 399 500 Functional Schematic Figure 2...

Page 14: ...User Manual CHAPTER 2 FUNCTIONAL OVERVIEW OMM 0100_E GF 146 11 15 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 14 of 170 2 5 2 AM 750 Functional Schematic Figure 2 4 750 Boiler Wate...

Page 15: ...er Manual CHAPTER 2 FUNCTIONAL OVERVIEW OMM 0100_E GF 146 11 15 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 15 of 170 2 5 3 AM 1000 Functional Schematic Figure 2 5 AM 1000 Boiler Wa...

Page 16: ...rent 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...

Page 17: ...ater Heater User Manual CHAPTER 2 FUNCTIONAL OVERVIEW OMM 0100_E GF 146 11 15 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 17 of 170 2 6 Main Components 2 6 1 Burner Figure 2 7 Burne...

Page 18: ...M Series Boiler Water Heater User Manual CHAPTER 2 FUNCTIONAL OVERVIEW OMM 0100_E GF 146 11 15 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 18 of 170 Figure 2 8 Burner Main Component...

Page 19: ...ser Manual CHAPTER 2 FUNCTIONAL OVERVIEW OMM 0100_E GF 146 11 15 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 19 of 170 2 6 2 AM Series 199 and 250 Main Components Figure 2 9 AM Seri...

Page 20: ...Boiler Water Heater User Manual CHAPTER 2 FUNCTIONAL OVERVIEW OMM 0100_E GF 146 11 15 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 20 of 170 Figure 2 10 AM Series 199 and 250 Main C...

Page 21: ...Boiler Water Heater User Manual CHAPTER 2 FUNCTIONAL OVERVIEW OMM 0100_E GF 146 11 15 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 21 of 170 Figure 2 11 AM Series 199 and 250 Main C...

Page 22: ...ser Manual CHAPTER 2 FUNCTIONAL OVERVIEW OMM 0100_E GF 146 11 15 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 22 of 170 2 6 3 AM Series 399 and 500 Main Components Figure 2 12 AM Ser...

Page 23: ...Boiler Water Heater User Manual CHAPTER 2 FUNCTIONAL OVERVIEW OMM 0100_E GF 146 11 15 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 23 of 170 Figure 2 13 AM Series 399 and 500 Main C...

Page 24: ...Boiler Water Heater User Manual CHAPTER 2 FUNCTIONAL OVERVIEW OMM 0100_E GF 146 11 15 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 24 of 170 Figure 2 14 AM Series 399 and 500 Main C...

Page 25: ...er Manual CHAPTER 2 FUNCTIONAL OVERVIEW OMM 0100_E GF 146 11 15 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 25 of 170 2 6 4 AM Series 750 and 1000 Main Components Figure 2 15 AM Ser...

Page 26: ...Boiler Water Heater User Manual CHAPTER 2 FUNCTIONAL OVERVIEW OMM 0100_E GF 146 11 15 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 26 of 170 Figure 2 16 AM Series 750 and 1000 Main C...

Page 27: ...Boiler Water Heater User Manual CHAPTER 2 FUNCTIONAL OVERVIEW OMM 0100_E GF 146 11 15 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 27 of 170 Figure 2 17 AM Series 750 and 1000 Main C...

Page 28: ...AM Series Boiler Water Heater User Manual CHAPTER 2 FUNCTIONAL OVERVIEW OMM 0100_E GF 146 11 15 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 28 of 170 This page intentionally blank...

Page 29: ...t or similar location where heavier than air gas might collect Appliances so fueled shall not be installed in an above grade under oor space or basement unless such location is provided with an approv...

Page 30: ...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 th...

Page 31: ...s 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 Installat...

Page 32: ...ces 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 Clear...

Page 33: ...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...

Page 34: ...ove 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...

Page 35: ...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...

Page 36: ...o 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...

Page 37: ...trations 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...

Page 38: ...g 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...

Page 39: ...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 fol...

Page 40: ...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 G...

Page 41: ...t 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 Fig...

Page 42: ...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 th...

Page 43: ...on Fri 8 am 5 pm EST Page 43 of 170 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 unit...

Page 44: ...ons 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 op...

Page 45: ...undesirable The total hardness 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 cre...

Page 46: ...ol is toxic and can attack gaskets and seals used in hydronic systems 4 5 Floor Radiant Heating Systems Boilers The setting of parameter 3015 in the Factory Menu see Appendix B determines the maximum...

Page 47: ...installation the temperature sensor must be relocated to the system piping For multiple unit installations using the AM Cascade Sequencer the cascade header temperature sensor included must be instal...

Page 48: ...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 operation Pump Recirculation pump should be s...

Page 49: ...u must consult 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 fact...

Page 50: ...ll connection at the same location as the expansion tank connection to the system 4 11 Circulator Heating Pump AM Series boilers and water heaters must be tted with a circulator pump The water resista...

Page 51: ...ing 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...

Page 52: ...igure 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 he...

Page 53: ...emperature 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 p...

Page 54: ...ter Heater User Manual CHAPTER 4 INSTALLATION PIPING OMM 0100_E GF 146 11 15 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 54 of 170 Figure 4 7 AM Water Heater Piping Example Models A...

Page 55: ...ains through pipe C Figure 4 8 and E Figure 4 9 and empties into the floor drain or drain pan F Fig 4 9 NOTE In newer units hose A Fig 4 8 attaches to a port at the bottom of flue rather than the side...

Page 56: ...6 of 170 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 boiler...

Page 57: ...5 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...

Page 58: ...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 t...

Page 59: ...nagement device Refer to the AM Series MODBUS User Manual GF 146 MB which is available from AERCO technical support and the AERCO website www aerco com 5 1 5 Connection to a LWCO Device Use only LWCO...

Page 60: ...ameter 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...

Page 61: ...to an Indirect Water Heater 1 Ensure that water connections are first made per examples in Figures 4 6 or 4 8 2 Open the boiler electrical junction box cover and connect the leads from the indirect w...

Page 62: ...hat parameter 2003 is set to 0 zero 6 The storage tank pump must be connected to terminals 113 and 114 of the electrical junction box See Figure 5 3 a eld supplied pump relay must be installed if the...

Page 63: ...INSTALLATION ELECTRICAL OMM 0100_E GF 146 11 15 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 63 of 170 Figure 5 6 AMR Recirculation Pump Pump Relay and LWCO Wiring Other Wiring Not...

Page 64: ...M Series Boiler Water Heater User Manual CHAPTER 5 INSTALLATION ELECTRICAL OMM 0100_E GF 146 11 15 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 64 of 170 This page intentionally blan...

Page 65: ...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 po...

Page 66: ...e 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...

Page 67: ...ater User Manual CHAPTER 6 INSTALL VENT COMBUSTION AIR PIPING OMM 0100_E GF 146 11 15 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 67 of 170 Figure 6 1 Acceptable Vent Air Piping Met...

Page 68: ...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...

Page 69: ...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 set...

Page 70: ...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 instal...

Page 71: ...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 sh...

Page 72: ...ustion 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 f...

Page 73: ...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 fin...

Page 74: ...o 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 thr...

Page 75: ...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...

Page 76: ...end 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 a...

Page 77: ...T Page 77 of 170 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 mus...

Page 78: ...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 free...

Page 79: ...170 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 s...

Page 80: ...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...

Page 81: ...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...

Page 82: ...ultiple 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 b...

Page 83: ...ric 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 le...

Page 84: ...es Boiler Water Heater User Manual CHAPTER 6 INSTALL VENT COMBUSTION AIR PIPING OMM 0100_E GF 146 11 15 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 84 of 170 This page intentionally...

Page 85: ...s 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 incom...

Page 86: ...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 comp...

Page 87: ...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 18...

Page 88: ...rating according to C302 7 See aerco com for further information For installations at higher altitudes in the United States follow local codes or in the absence of local codes follow ANSI Z223 1 NFPA...

Page 89: ...meter 3002 4 Press RESET button once to select displayed 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 rig...

Page 90: ...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...

Page 91: ...t 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 t...

Page 92: ...6 11 15 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 92 of 170 Figure 7 6 Changing the Display Connections AM 750 1000 Shown Figure 7 7 PROPANE LP GAS Label Figure 7 8 NATURAL GAS la...

Page 93: ...Make sure that the user keeps 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 poisoni...

Page 94: ...ure for which the heating system 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 ttin...

Page 95: ...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 operat...

Page 96: ...ation 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 re only when there is a call for heat and the heating temperature settin...

Page 97: ...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 inf...

Page 98: ...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...

Page 99: ...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 s...

Page 100: ...ow 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 acce...

Page 101: ...eck 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 step...

Page 102: ...lve 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 ll the heating circuit s...

Page 103: ...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 suppl...

Page 104: ...ms 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 bel...

Page 105: ...ut 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...

Page 106: ...ant 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...

Page 107: ...perature 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 para...

Page 108: ...ric 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 P...

Page 109: ...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 e...

Page 110: ...the DHW pump ON OFF 1012 Calculated CH setpoint when outdoor sensor s activated only for 199 and 250 mode Boilers Only F 1040 Burner 1 Actual Fan speed rpm min 1041 Burner 1 Ignition fan speed rpm mi...

Page 111: ...he list of parameters press buttons and 3 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 usin...

Page 112: ...rature F 0 to 36 28 28 2062 DHW post pump time sec 10 to 255 240 N A 2063 DHW max priority time min 1 to 60 30 N A 2067 DHW priority 0 TIME DHW has priority to CH during DHW max priority time 2063 1 O...

Page 113: ...h to OFF 2 Simultaneously press and hold the RESET and buttons 3 While the RESET and buttons are both depressed turn the power switch to ON 4 Wait until the word init is displayed in the control panel...

Page 114: ...A 1 1 0 1 0 3005 Burner apper valve 0 Disabled 4 Enabled 8 N A 12 N A 4 4 4 4 4 3006 Water ow sensor 0 Disabled 16 N A 32 N A 48 N A 48 48 48 48 48 3007 Condensate blocked drain detector EnAb Enabled...

Page 115: ...to 194 F 68 F 68 F 68 F N A N A 3017 Maximum supply temperature This 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...

Page 116: ...AM Series Boiler Water Heater User Manual CHAPTER 9 OPERATION OMM 0100_E GF 146 11 15 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 116 of 170...

Page 117: ...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 func...

Page 118: ...replaced it is mandatory to inform the manufacturer to prevent serious damage and a possible dangerous condition Failure to comply with this requirement can result in excessive levels of carbon monox...

Page 119: ...rature does not increase replace the flue gas sensor or the control board 9 20 Diagnostics Blocking Err Errors Blocking errors are generated by a permanent fault There is no way to unlock the unit oth...

Page 120: ...ion 10 24 replace it Err 62 Blocked drain switch is active This error will stop all modules a Check if the condensate drain is blocked b Check if the condensate tank is blocked a Remove any obstructio...

Page 121: ...r ow Check water ow into the system parameter 1062 it must be higher than parameter 3035 Increase the water ow into the system Check for any obstructions in the water system inlets Err 115 Multiple bu...

Page 122: ...levels of CO to enter the mechanical room Ensure vent is intact and free of any obstructions or restrictions 9 22 Unit Shut Down To shut the unit down perform the following Shutting Down the Unit 1 Tu...

Page 123: ...AM Series Boiler Water Heater User Manual CHAPTER 9 OPERATION OMM 0100_E GF 146 11 15 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 123 of 170 This page intentionally blank...

Page 124: ...ICIAN USER MAINTENANCE Annual Startup and Maintenance Address reported problems Check all piping for gas leaks Verify ue and air lines in good condition and sealed tight Check system water pressure sy...

Page 125: ...nit 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...

Page 126: ...inspection agency not 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 follo...

Page 127: ...and condensate trap for signs of weeping or leakage If you detect signs of leakage immediately contact your quali ed service technician to inspect the boiler and system Ensure there is sufficient neu...

Page 128: ...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 inch...

Page 129: ...ceeding 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 i...

Page 130: ...et 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 fr...

Page 131: ...e 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 C...

Page 132: ...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...

Page 133: ...tions 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...

Page 134: ...acement 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 fa...

Page 135: ...bly 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...

Page 136: ...f 170 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...

Page 137: ...e Detection Electrode Positioning 2 To insure correct functioning of the burner the distances listed below should be carefully veri ed by hand using calipers The distance between the ignition electrod...

Page 138: ...n 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 Pul...

Page 139: ...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 be...

Page 140: ...n tank must be lled with water to prevent ue gas emissions from escaping during unit operation Failure to comply with this requirement can result in dangerous levels of carbon monoxide 9 Open the manu...

Page 141: ...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...

Page 142: ...ool 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...

Page 143: ...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 with the values shown in...

Page 144: ...en 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...

Page 145: ...05028 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 ELECTRO...

Page 146: ...f 170 10 27 1 AM Series 399 1000 Model Wiring Diagram WARNING Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper oper...

Page 147: ...0 526 0288 Mon Fri 8 am 5 pm EST Page 147 of 170 WARNING Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation...

Page 148: ...0 526 0288 Mon Fri 8 am 5 pm EST Page 148 of 170 WARNING Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation...

Page 149: ...0288 Mon Fri 8 am 5 pm EST Page 149 of 170 WARNING Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation afte...

Page 150: ...0 526 0288 Mon Fri 8 am 5 pm EST Page 150 of 170 WARNING Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation...

Page 151: ...e sensor 16 Modulating PWM fan 17 Back flue preventer switch Flapper valve switch 19 Water pressure sensor 20 Gas valve 22 Detection electrode 28 Blocked flue pressure switch 29 Condensate blocked dra...

Page 152: ...AM Series Boilers and Water Heaters User Manual CHAPTER 10 MAINTENANCE OMM 0100_E GF 146 11 15 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 152 of 170 This page intentionally blank...

Page 153: ...ter inch 4 4 6 6 Max length venting 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...

Page 154: ...tonium 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 Capaci...

Page 155: ...SPARE PARTS OMM 0100_E GF 146 11 15 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 155 of 170 SECTION 12 SPARE PARTS DRAWINGS LISTS 12 1 AM 399 500 Spare Parts Drawings Figure 12 1 AM...

Page 156: ...iler Water Heater User Manual CHAPTER 12 SPARE PARTS OMM 0100_E GF 146 11 15 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 156 of 170 Figure 12 2 AM 399 500 General Assembly Parts dra...

Page 157: ...Boiler Water Heater User Manual CHAPTER 12 SPARE PARTS OMM 0100_E GF 146 11 15 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 157 of 170 Figure 12 3 AM 399 500 Burner Fan Assembly Part...

Page 158: ...6 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 BO...

Page 159: ...OW 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...

Page 160: ...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 NT...

Page 161: ...Manual CHAPTER 12 SPARE PARTS OMM 0100_E GF 146 11 15 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 161 of 170 12 3 AM 750 1000 Spare Parts Drawings Figure 12 4 AM 750 1000 General As...

Page 162: ...iler Water Heater User Manual CHAPTER 12 SPARE PARTS OMM 0100_E GF 146 11 15 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 162 of 170 Figure 12 5 AM 750 1000 General Assembly Parts Dr...

Page 163: ...Boiler Water Heater User Manual CHAPTER 12 SPARE PARTS OMM 0100_E GF 146 11 15 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 163 of 170 Figure 12 6 AM 750 1000 Burner Fan Assembly Par...

Page 164: ...dels 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...

Page 165: ...lve 54 61203024 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...

Page 166: ...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 IGNITI...

Page 167: ...t 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...

Page 168: ...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...

Page 169: ...ual APPENDIX A CONTROL PANEL OPERATION FLOW CHART OMM 0100_E GF 146 11 15 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 169 of 170 APPENDIX A CONTROL PANEL OPERATION CHART Figure A 1...

Page 170: ...nges and improvements fixed all tables Added buffer tank installation instructions section s 3 11 3 16 corrected AMR electrical diag added new AMR images removed drain pan from images parts list repla...

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