Installation, Operation & Maintenance Manual (IOMM) Natural Gas or Propane Modulating and Condensing Boilers and Water Heaters Including Models: GF-146 USER MANUAL Installation, Operation and Maintenance Boilers • • • • 399 / 500 / 750 / 1000 AM 399B AM 500B AM 750B AM 1000B Gas-Fired Boilers and Water Heaters 399 / 500 / 750 / 1000 Pending Gas-Fired Boilers and Water Heaters Water Heaters • • • • AM 399W AM 500W AM 750W AM 1000W Pending AM 750/1000 Latest Update: 07/14/2014 Page 1 of 156 PR
AM Series Boilers and Water Heaters Installation, Operation & Maintenance Manual (IOMM) DISCLAIMER The information contained in this manual is subject to change without notice from AERCO International, Inc. AERCO makes no warranty of any kind with respect to this material, including, but not limited to, implied warranties of merchantability and fitness for a particular application.
AM Series Boilers and Water Heaters Installation, Operation & Maintenance Manual (IOMM) TABLE OF CONTENTS FOREWORD ................................................................................................................ 7 CHAPTER 1: GENERAL INFORMATION ........................................................................ 9 1.1 WARNINGS & CAUTIONS ..................................................................................................................... 9 1.2 EMERGENCY SHUTDOWN .......
AM Series Boilers and Water Heaters Installation, Operation & Maintenance Manual (IOMM) 3.14.1 Power Supply Cable Connection – Boilers and Water Heaters .....................................................................52 3.14.1.1 Connecting Units in Cascade (Boilers or Water Heaters) ......................................................................54 3.14.2 0-10 VDC Input Connections – Boilers & Water Heaters ..................................................................................56 3.14.
AM Series Boilers and Water Heaters Installation, Operation & Maintenance Manual (IOMM) 4.1.1 Filling the Condensate Neutralizer .................................................................................................................89 4.1.2 Filling the Heating System ..............................................................................................................................90 4.2 GENERAL WARNINGS CONCERNING THE GAS SUPPLY ..........................................................
AM Series Boilers and Water Heaters Installation, Operation & Maintenance Manual (IOMM) 6.1.9 Relief Valve Inspection..................................................................................................................................117 6.1.10 Unit Vicinity Inspection ...............................................................................................................................117 6.1.11 Pressure Gauge Inspection .................................................................
AM Series Boilers and Water Heaters FORWARD FOREWORD The Advanced Modular (AM) Series represents the latest in high efficiency, condensing boiler and water heater technology. The AM Series has a unique modular design that provides exceptional reliability, serviceability, and fuel savings from 399 to 1000 MBTU. Each unit is comprised of between two and four independent thermal modules firing up to 250 MBTU each at 5:1 individual turndown.
AM Series Boilers and Water Heaters CHAPTER 1 – GENERAL INFORMATION (This page intentionally blank) Page 8 of 156 PRI - 07/14/14 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
AM Series Boilers and Water Heaters CHAPTER 1 – GENERAL INFORMATION CHAPTER 1: GENERAL INFORMATION 1.1 Warnings & Cautions In addition to all the requirements included in this AERCO Instruction Manual, the installation of units MUST conform with local building codes, or, in the absence of local codes, ANSI Z223.1 (National Fuel Gas Code Publication No. NFPA-54) for gas-fired boilers and ANSI/NFPASB for LP gas-fired boilers.
AM Series Boilers and Water Heaters CHAPTER 1 – GENERAL INFORMATION NOTE When calling or writing about the boiler, have the unit model and serial number as seen on the unit rating plate. CAUTION! Do not use petroleum-based cleaning or sealing compounds in the boiler system. Gaskets and seals in the system may be damaged. This can result in substantial property damage.
AM Series Boilers and Water Heaters CHAPTER 1 – GENERAL INFORMATION OFF. OFF. OMM-0100_0B GF-146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
AM Series Boilers and Water Heaters CHAPTER 1 – GENERAL INFORMATION 1.2 Emergency Shutdown If overheating occurs or the gas supply fails to shut off, close the manual gas shutoff valve (Figure 1-1) located external to the unit. NOTE The Installer must identify and indicate the location of the emergency shutdown manual gas valve to operating personnel.
AM Series Boilers and Water Heaters CHAPTER 2 – FUNCTIONAL OVERVIEW CHAPTER 2: FUNCTIONAL OVERVIEW 2.1 Introduction This Chapter provides a general description of the AERCO AM Series boilers and water heaters. 2.2 Intended Use – Boilers The gas-fired condensing AM Series boilers are designed to be used in central heating systems. Any other use is prohibited. Heat is always guaranteed for the production of domestic hot water since it is given priority over space heating demands.
AM Series Boilers and Water Heaters CHAPTER 2 – FUNCTIONAL OVERVIEW 2.4 AM Series Component Diagrams Figure 2-1: 399 / 500 / 750 / 1000 Burner Components (1 of 2) Page 14 of 156 PRI - 07/14/14 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
AM Series Boilers and Water Heaters CHAPTER 2 – FUNCTIONAL OVERVIEW Figure 2-2: 399 / 500 / 750 / 1000 Burner Components (2 of 2) OMM-0100_0B GF-146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
AM Series Boilers and Water Heaters CHAPTER 2 – FUNCTIONAL OVERVIEW Figure 2-3: 399 / 500 Main Components (1 of 2) Page 16 of 156 PRI - 07/14/14 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
AM Series Boilers and Water Heaters CHAPTER 2 – FUNCTIONAL OVERVIEW Figure 2-4: 399 / 500 Main Components (2 of 2) OMM-0100_0B GF-146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
AM Series Boilers and Water Heaters CHAPTER 2 – FUNCTIONAL OVERVIEW Figure 2-5: 399 / 500 Rear Components Page 18 of 156 PRI - 07/14/14 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
AM Series Boilers and Water Heaters CHAPTER 2 – FUNCTIONAL OVERVIEW Figure 2-6: 750 / 1000 Main Components (1 of 2) OMM-0100_0B GF-146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
AM Series Boilers and Water Heaters CHAPTER 2 – FUNCTIONAL OVERVIEW Figure 2-7: 750 / 1000 Main Components (2 of 2) Page 20 of 156 PRI - 07/14/14 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
AM Series Boilers and Water Heaters CHAPTER 2 – FUNCTIONAL OVERVIEW Figure 2-8: 750 / 1000 Rear Components OMM-0100_0B GF-146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
AM Series Boilers and Water Heaters CHAPTER 2 – FUNCTIONAL OVERVIEW 2.5 AM Series Functional Schematics 2.5.1 AM 399 / 500 Functional Schematic Figure 2-9: 399 / 500 (Boiler & Water Heater) Functional Schematic Page 22 of 156 PRI - 07/14/14 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
AM Series Boilers and Water Heaters CHAPTER 2 – FUNCTIONAL OVERVIEW 2.5.2 AM 750 Functional Schematic Figure 2-10: 750 (Boiler & Water Heater) Functional Schematic OMM-0100_0B GF-146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
AM Series Boilers and Water Heaters CHAPTER 2 – FUNCTIONAL OVERVIEW 2.5.3 AM1000 Functional Schematic Figure 2-11: 1000 (Boiler & Water Heater) Functional Schematic Page 24 of 156 PRI - 07/14/14 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
AM Series Boilers and Water Heaters CHAPTER 2 – FUNCTIONAL OVERVIEW 2.5.4 Boiler Efficiency in Outdoor Reset Mode When the outdoor reset is activated (an outside sensor is connected), this boiler is designed to always work at the maximum efficiency. It will automatically change the supply temperature in relation with the outdoor temperature (Outdoor reset). The graph in Figure 2-12 shows a typical system. Outdoor reset curves are adjustable. .
AM Series Boilers and Water Heaters CHAPTER 2 – FUNCTIONAL OVERVIEW (This page intentionally blank) Page 26 of 156 PRI - 07/14/14 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION CHAPTER 3: INSTALLATION 3.1 Choosing the Installation Location This section describes the general installation considerations for the AM Series units. WARNING! Provisions for combustion air and ventilation of the boiler room are always required, regardless whether the combustion air is taken from the outside (Direct Vent, sealed combustion) or inside (room air for combustion).
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION 3.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION 3.3 Safety Concerns WARNING! Do not store any flammable materials or liquids in the immediate vicinity of the boiler. 3.4 Closet and Alcove Installation It is forbidden to install the AM Series boilers or water heaters in a closet or in an alcove site. 3.5 Clearances for Installation and Servicing Figures 3-1 and 3-2 show the minimum clearances required for installation and servicing.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION Figure 3-2: Recommended Minimum Clearances for Servicing (AM750 / AM1000) NOTE Service clearances are minimum required clearances for ease of access, but larger service clearances are always preferred. 3.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION 3.7 Vent and Combustion Air Piping This boiler requires a special vent system, designed for pressurized venting. The boiler is to be configured for either direct vent installation or for installation using room combustion air. When room combustion air is considered, see Section 3.16. Vent and air may be vented vertically through the roof or out a side wall, unless otherwise specified.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION 3.10 Unpacking and Installing the Unit Unpacking Instructions 1. Remove the outer shipping carton from the water heater. 2. Remove the lower front cover “A” at front of the unit by pulling it forward to access and remove the screw and washer “B” (Figure 3-3). B A Figure 3-3: Removing the Unit from Wood Pallet (Front) 3. Remove the screw and washer “C” at the rear of the unit (Figure 3-4).
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION Unpacking Instructions (Cont.) 4. Install the two factory supplied eyebolts “D” on the upper side of the unit and attach chains or straps to lifting ring/hook “E” as shown in Figure 3-5. Figure 3-5: Removing the Unit from Wood Pallet (Lifting) Using the appropriate lifting equipment, hoist the unit from the wood pallet. The weight of each models are as follows: Model AM399 AM500 AM750 AM1000 Weight (lbs.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION 3.11 Supply and Return Piping - Boilers Standard connections and dimensions for all AM Series units are shown in Figure 3-7. Models AM 399/500 Models AM 750/1000 Figure 3-7: AM 399/500 & 750/1000 Installation Connection Dimensions Page 34 of 156 PRI - 07/14/14 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION 3.11.1 Water Quality - Boilers • Before connecting the boiler to the heating system, the heating system must be thoroughly flushed to remove sediment, flux, filings and other foreign matter. The heat exchanger can be damaged by build-up of corrosion due to sediment. • An approved inhibitor should be added to the heating system water to prevent limestone and magnetite deposits from forming and to protect the boiler from galvanic corrosion.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION WARNING! Never use non-approved additives or toxic boiler treatment chemicals in the heating system. Any additives introduced into the heating system must be recognized as safe. Use only inhibited propylene glycol solutions, which are specifically formulated for hydronic systems. Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems. 3.11.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION • • Flow Switch/LWCO: A flow switch comes with every unit and must be field installed. For more information about the flow switch or optional LWCO, see Section 3.11.7. Indirect water heaters: Feld supplied. This boiler may be piped to an indirect water heater to heat domestic hot water with the space heat transfer medium. The indirect water heater is connected to the system supply piping.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION 3.11.6 Safety Relief Valve - Boilers The boiler is supplied with a safety relief valve on each module that is factory installed. Each pressure relief valve is set to 50 PSI. If a higher or lower rated PRV is required it must be field supplied and installed. If an AM Series H-Stamped unit is being used directly in a domestic water heating application the relief valves must be replaced with appropriate temperature & pressure relief valves.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION 3.11.7 Flow Switch A flow switch is required to be installed on every unit (Figure 3-9). This flow switch is included with the unit and must be field-installed. Cut the paddle to length according to package directions and install in a tee on the unit outlet piping. You must NOT install any valves in between the unit and the flow switch.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION 3.11.9 Expansion Tank and Makeup Water - Boilers Install an expansion tank. Ensure the expansion tank is properly sized for the boiler volume and the system volume, temperature and pressure. CAUTION! Undersized expansion tanks will cause system water to be lost through the pressure relief valve and cause additional makeup water to be added to the system.
AM Series Boilers and Water Heaters BACKFLOW PREVENTION VALVES CHAPTER 3 – INSTALLATION Figure 3-12: Boilers - 399B/500B Piping Example OMM-0100_0B GF-146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
AM Series Boilers and Water Heaters BACKFLOW PREVENTION VALVES CHAPTER 3 – INSTALLATION Figure 3-13: Boilers - 750B / 1000B Piping Example 3.11.12 Domestic Hot Water System Piping with Indirect Water Heater - Boilers See Figures 3-16 and 3-17, for recommended piping for the AM Series water heater. This recommended piping configuration ensures priority is given to the production and recovery of domestic hot water (DHW).
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION 3.12 Hot and Cold Water Piping – Water Heaters This section applies only to water heaters. See Section 3.11 for piping of boilers. • • • • All water system piping must be installed in accordance with the ANSI/ASME Boiler and Pressure Vessel Code, Section IV. All applicable local codes and ordinances must also be followed.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION 12. Filter: Field supplied. Install a filter or equivalent multipurpose strainer at the cold water inlet connection of the water heater to remove system particles from older hydronic systems and protect newer systems. 13. Flow Switch: Factory Supplied. See Section 3.11.7. Install the heater so the gas ignition system components are protected from water (dripping, spraying, etc.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION 3.12.5 Sizing the Water System – Water Heaters Size the pump, piping, and system components required in the water system using recognized design methods. 3.12.6 Scalding – Water Heaters This water heater can deliver scalding temperature water at any faucet in the system. Be careful whenever using hot water to avoid scalding injury. Certain appliances such as dishwashers and automatic clothes washers may require increased temperature water.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION 3.12.7 Water Chemistry – Water Heaters The water heater pressure drops (see Figure 3-14) are based on potable water with a hardness of 5 to 25 grains per gallon and a total dissolved solids not exceeding 350 ppm. Consult the manufacturer when heating potable water exceeding these specifications.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION Figure 3-15: AM Series Water Heater Water Velocity and Flow Graph OMM-0100_0B GF-146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
AM Series Boilers and Water Heaters BACKFLOW PREVENTION VALVE CHAPTER 3 – INSTALLATION Figure 3-16: Water Heaters - 399W/ 500W Piping Example Page 48 of 156 PRI - 07/14/14 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
AM Series Boilers and Water Heaters BACKFLOW PREVENTION VALVE CHAPTER 3 – INSTALLATION Figure 3-17: Water Heaters - 750W/ 1000W Piping Example OMM-0100_0B GF-146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION 3.13 Condensate Disposal WARNING! The condensate trap, as shown in Figure 3-18, item “B”, MUST be filled with water or combustion gases will enter the room. The condensate neutralizer box must be installed into the unit, exactly as shown in Figures 2-3 and 2-4 (399/500) or Figures 2-6 and 2-7 (750/1000).
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION Figure 3-19: Condensate Box Draining The condensate drainage system is designed to empty all the condensate produced by one boiler only. Each boiler must be equipped with its own condensate drainage system or the drainage system may malfunction A condensate removal pump is required if the boiler is below the drain. When installing a condensate pump, select one approved for use with condensing boilers and furnaces.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION 3.14 Electrical Connections 3.14.1 Power Supply Cable Connection – Boilers and Water Heaters Provide and 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 3-20. Figure 3-20: Line Voltage Connection Figure 3-21: Boiler Electrical Junction Box Connections Page 52 of 156 PRI - 07/14/14 AERCO International, Inc.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION Figure 3-22: Water Heater Electrical Junction Box Connections (with Small Storage Tank) Figure 3-23: Water Heater Electrical Junction Box Connections (with Large Storage Tank) OMM-0100_0B GF-146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION 3.14.1.1 Connecting Units in Cascade (Boilers or Water Heaters) To connect the heater in cascade you have to follow the electrical connections as per Figure 324. A maximum of eight heaters can be connected in a cascade (Figure 3-24 shows a connection of four heaters). After the electrical power connection is made, activate the BUS communication to the HC command by performing the following: Activating the Cascade BUS Communication 1.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION Figure 3-24: Cascading AM Units (Boiler or Water Heater) Electrical Connections OMM-0100_0B GF-146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION 3.14.2 0-10 VDC Input Connections – Boilers & Water Heaters The AM Series models 500, 750 and 1000 are factory supplied with a 0-10 VDC interface (the 399 model can be equipped with one as an option). This 0-10 VDC interface allows driving the appliance via a 0-10 VDC analog input.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION 3.14.4 On/Off Control (Enable/Disable) For remote enabling/disabling of a boiler, follow the instructions below. Wiring a Thermostat to the Boiler 1. Remove the boiler front cover according to the instructions in Section 6.1.15. 2. Connect the leads of a two conductor cable (with a minimum cross section of #18 AWG) to the thermostat and run the cable to the boiler electrical junction box. 3.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION Connecting the Outdoor Temperature Sensor to the Boiler 1. Remove the boiler front cover according to the instructions in Section 6.1.15. 2. Connect the leads of a two conductor cable (with a minimum cross section of #18 AWG) to the outdoor temperature sensor and run the cable to the boiler electrical junction box. 3.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION Priority selection is a functionality that toggles between heating and DHW demand when they are both active at the same time. The priority selection is set with the 2067 (DHW Priority) parameter in the Installer Menu (see Section 5.4). • If parameter 2067 is set to “0”, the boiler will load the indirect water heater for the time set in parameter 2063 and, after that, heating will take place for the same amount of time.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION 3.16 Venting and Combustion Air Piping WARNING! DO NOT connect this gas appliance, or any other appliance using a positive venting pressure, in a common vent system with other equipment! Failure to comply with this WARNING could result in the accumulation of carbon monoxide gas which can cause severe personal injury or death. 3.16.1 Combustion Air Contamination Prevention Install air inlet piping only as described in all of Section 3.16.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION • Refrigeration repair shops; • Photo processing plants; • Auto body shops; • Plastic manufacturing plants; • Furniture refinishing areas and establishments; • Remodeling areas; • Garages with workshops. 3.16.2 General Venting and Air Piping Systems The AM Series of boilers and water heaters requires a special vent system, designed for pressurized venting.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION Figure 3-27: Acceptable Vent/Air Piping Methods for AM Series Units Page 62 of 156 PRI - 07/14/14 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION 3.16.3 Min/Max Allowable Combustion Air and Vent Piping Lengths The maximum length of the two pipes vent system is 120 equivalent feet (air intake plus flue exhaust). However, each single pipe can’t be longer than 60 feet. Each 45° elbow inserted in the venting system has a loss of pressure equivalent to 3 feet of linear pipe Each 90° elbow inserted in the venting system has a loss of pressure equivalent to 6 feet of linear pipe.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION Polypropylene and stainless steel pipe may require an adapter (not provided) to transition between the air inlet connection on the appliance and the air inlet pipe. Contact the vent manufacturer for these shorter pieces. The use of insulated material for the combustion air inlet pipe is recommended in cold climates to prevent the condensation of airborne moisture in the incoming combustion air. 3.16.5.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION 3.16.5.3 Air Intake and Vent Starter Pieces Venting must be supported per guidelines listed in the National Mechanical Code, Section 305, Table 305.4 or as local codes dictate. To connect a vent pipe to the air intake and vent outlet, proceed as follows while referring to Figures 3-28 and 3-29: Installing the Air Intake and Vent Connections 1. 2. 3. 4. Install heater adapter “P” above inlet air opening “M” with gasket “D” and bolts “E”.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION WARNING! Do not insulate PVC/CPVC exhaust pipe nor install into an enclosure, closet, alcove or any other obstruction thereby preventing the cooling of the exhaust pipe. Installation must comply with local requirements and with the National Fuel Gas Code, ANSI Z223.1 for U.S. installations or CSA B149.1 for Canadian installations. For installation in Canada, vent pipe system must be certified to ULC-S636 (see Table 3-2).
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION 3.16.5.5 Combustion Air and Ventilation Openings Outdoor combustion air shall be provided through opening(s) to the outdoors. WARNING! Make sure that combustion air and ventilation openings are sufficiently sized and no reduction or closure of openings takes place. 3.16.5.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION 3. The vent piping must terminate in an elbow pointed outward as shown in Figure 3-31 or 332. CAUTION! Do not exceed the maximum lengths of the outside vent piping shown in Figure 3-28. Excessive length exposed to the outside could cause freezing of condensate in the vent pipe, resulting in potential heater shutdown. 4. Maintain clearances as shown in Figure 3-30. Vent must terminate as follows: • At least 6 feet from adjacent walls.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION 3.16.5.9 Sidewall Termination - Two pipes Installation must comply with local requirements and with the National Fuel Gas Code, ANSI Z223.1 for U.S. installations or CSA B149.1 for Canadian installations. CAUTION! A gas vent extending through an exterior wall shall not terminate adjacent to a wall or below building extensions such as eaves, parapets, balconies, or decks. 3.16.5.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION If space permits: Figure 3-31: Sidewall Termination of Air and Vent Pipes 5. Maintain clearances as shown in Figure 3-30. a) Vent must terminate: • At least 6 feet from adjacent walls. • No closer than 12 inches below roof overhang. • At least 7 feet above any public walkway. • At least 3 feet above any forced air intake within 10 feet.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION 3.16.5.11 Installing Vent and Air Piping into Sidewall Install vent and air piping through sidewalls as follows: Installing Vent and Air Piping into Sidewall 1. Install air pipe through wall: a) Cut a hole for the air pipe. Size the air pipe hole as close as desired to the air pipe outside diameter. 2. Install vent pipe through wall: a) Cut a hole for the vent pipe.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION Figure 3-32: Two-Pipe Multi-Unit Air and Vent Sidewall Termination Figure 3-33: Multiple Air and Vent Pipes Sidewall Termination Page 72 of 156 PRI - 07/14/14 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION 3.16.5.14 Sidewall Termination – Concentric Vent A concentric vent termination must terminate outside the structure and must be installed as shown in Figure 3-34. The termination opening must be protected from rain, see Figure 3-35. Figure 3-34: Concentric Sidewall Termination Clearances Figure 3-35: Concentric Sidewall Termination Clearances (Side View) OMM-0100_0B GF-146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION 3.16.5.15 Sidewall Termination Installation Install a concentric vent termination into a sidewall as follows: Installing Concentric Vent Termination into Sidewall 1. Determine the best location for the termination (see Figures 3-34 and 3-35). 2. The total length of piping for vent or air must not exceed the limits given in Section 3.16.3. 3.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION 3.16.5.16 Multi-venting Sidewall Terminations When two or more direct vent appliances are vented near each other, each appliance must be individually vented and vent terminations may be installed as shown in Figure 3-36. It is important that vent terminations be made as shown to avoid recirculation of flue gas. Figure 3-36: Concentric Sidewall Multiple-Unit Termination Clearances 3.16.5.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION 3.16.5.18 Determining Location of Vertical Termination Locate the vertical 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 3.16.3. 2. The vent must terminate at least 3 feet above the highest place in which the vent penetrates the roof and at least 2 feet above any part of a building within 10 horizontal feet. 3.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION 3.16.5.19 Vertical Vent and Air Roof Termination Preparation Prepare for installation of vent and air termination into a roof as follows: Vertical Vent and Air Roof Termination Preparation 1. Air pipe penetration: cut a hole for the air pipe, sizing the air pipe hole as close as desired to the air pipe outside diameter. 2. Vent pipe penetration: a) Cut a hole for the vent pipe.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION 3.16.5.21 Installing Multiple Vent and Air Vertical Terminations Install multiple vent and air terminations in a roof as follows: Installing Vertical Multiple Vent and Air Roof Terminations 1. When terminating multiple units, terminate each vent/air connection as shown in Figure 338. 2. Place roof penetrations to obtain minimum clearance of 12 inches between edge of air intake elbow and adjacent vent pipe of another appliance for U.S.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION 3.16.5.22 Vertical Termination – Concentric Vent Both combustion air and vent pipes must attach to the termination. The termination must terminate outside the structure and must be installed as shown in Figure 3-39. 3.16.5.23 Determining Location of Vertical Concentric Vent Termination Locate the vertical concentric vent/air terminations using the following guidelines: 1.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION 3.17 Gas Supply Piping Check that the type and the pressure of the gas supplied correspond with those required for the heater as stated on the rating plate. Never use a gas different than that stated on the heater rating plate. A lockup style regulator is required on each unit any time the gas supply pressure may exceed 13” W.C. If gas supply pressure is between 3” and 13” individual regulators are recommended on every unit but not required.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION Connecting the Gas Supply to the Unit (Cont.) 4. Purge all air from the gas supply piping. 5. Before placing the appliance in operation, check the appliance and its gas connection for leaks. a) The appliance must be disconnected from the gas supply piping system during any pressure testing of that system at a test pressure in excess of 1/2 PSIG (3.5 kPa).
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION 3.17.2 Natural Gas Pipe Sizing Refer to the table below for pipe lengths and diameters. For additional gas pipe sizing information, refer to ANSI Z223.1 (or B149.1 for Canadian installations). Table 3-4: Gas Pipe Capacity for Natural Gas 3.17.2.1 Natural Gas Supply Pressure Requirements • • Install 100% lockup gas pressure regulator in supply line if inlet pressure can exceed 13”W.C. at any time. Adjust lockup regulator for 13” W.C. maximum.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION 3.17.4 Checking and Adjusting the Unit Inlet Gas Supply Pressure DO NOT adjust or attempt to measure gas valve outlet pressure. The gas valve is factory-set for the correct outlet pressure. This setting is suitable for natural gas and propane, requiring no field adjustment. Attempting to alter or measure the gas valve outlet pressure could result in damage to the valve, causing excessive levels of carbon monoxide.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION 3.17.5 High Altitude Operation AERCO is currently developing the high altitude calibration procedure. For further information, please contact AERCO applications engineering. For installations at higher altitudes in the United States, follow local codes or, in the absence of local codes, follow ANSI Z223.1/NFPA No. 54, The National Fuel Gas Code, and check and adjust the CO2 level following Section 4.7. 3.17.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION Gas Rating Conversion of Master Burner 1 You must convert Burner 1 (Master) first, and then convert each additional burner in the unit afterward. Refer to Figures 2-4 and 2-6 to locate Burner 1 (Master) and then perform the following steps: 1. Turn OFF power to the unit. 2. Gain access to the Factory Menu as follows: press and hold, at the same time, both the RESET and buttons while turning ON unit power.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION Gas Rating Conversion of Master Burner 1 (Cont.) 16. Check for any gas leaks on nut “H” as per Figure 3-42. 17. Turn the power ON to the unit. 18. Turn completely counter-clockwise screw “E” in Figure 3-45. 19. Check the gas supply pressure per Section 4.6. The minimum gas supply pressure must not be less than 3” W.C. (7.6 mbar) and the maximum gas supply pressure must not be higher than 13” W.C. (33 mbar). 20.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION Gas Rating Conversion of Burners 2, 3, and 4 After converting Burner 1 (Master), you must convert Burner 2, Burner 3 (if present), and Burner 4 (if present). Refer to Figure 3-46 and perform the following steps: 1. Turn the power OFF to the unit. Burner 2: 2. Disconnect plug “B” from connector “A”. 3. Connect plug “B” to connector “C”. 4. Repeat Step 1 through Step 20 of the previous instructions “Gas Rating Conversion of Master Burner”. 5.
AM Series Boilers and Water Heaters CHAPTER 3 – INSTALLATION Figure 3-46: Changing the Display Connections Figure 3-47: PROPANE (LP) GAS label Page 88 of 156 PRI - 07/14/14 Figure 3-48: NATURAL GAS label AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
AM Series Boilers and Water Heaters CHAPTER 4 – UNIT START-UP CHAPTER 4: UNIT START-UP 4.1 INITIAL START-UP REQUIREMENTS Before starting the heater, the user must be correctly instructed by the installer, on how to operate the heater, in particular: • Make sure that the user understands that combustion air and ventilation openings must not be restricted, closed, or modified in any way.
AM Series Boilers and Water Heaters CHAPTER 4 – UNIT START-UP 4.1.2 Filling the Heating System To fill the heating system, proceed as follows: CAUTION! The water’s pH must fall within the following limit: 7.5
AM Series Boilers and Water Heaters CHAPTER 4 – UNIT START-UP 4.2.1 Confirming the Unit’s Gas Type The type of gas and the gas supply pressure that the unit is set up for is listed on the rating label. The AM Series boilers and water heaters can operate using one of the following two gases: NATURAL GAS o Maximum supply pressure = 13” W.C. (33.0 mbar). o Minimum supply pressure = 3” W.C. (7.6 mbar). PROPANE (LP) GAS o Maximum supply pressure = 13” W.C. (33.0 mbar). o Minimum supply pressure = 3” W.C.
AM Series Boilers and Water Heaters CHAPTER 4 – UNIT START-UP 4.4 Boiler Startup Procedure This section applies only to AM Series boilers. Refer to the next section for starting an AM Series water heater. To start the boiler, do the following: Boiler Startup Procedure 1. Open the manual gas shut off valve (Figure 3-37), 2. Turn the unit power switch to ON (item “T” in Figure 4-1). NOTE The thermostat is adjusted to its lowest temperature position when shipped from the factory. 3.
AM Series Boilers and Water Heaters CHAPTER 4 – UNIT START-UP 4.6 Gas Supply Pressure Test DO NOT adjust or attempt to measure gas valve outlet pressure. The gas valve is factory-set for the correct outlet pressure. This setting is suitable for natural gas and propane, requiring no field adjustment. Attempting to alter or measure the gas valve outlet pressure could result in damage to the gas valve. Check the gas supply pressure by following the steps below: Gas Supply Pressure Test 1.
AM Series Boilers and Water Heaters CHAPTER 4 – UNIT START-UP Gas Supply Pressure Test (Cont.) 8. Generate a heat demand as follows, for appropriate type (boiler or water heater): • BOILER: by pressing button • WATER HEATER: by pressing button to its maximum setting. to its maximum setting. 9. Generate a heat demand as follows, for appropriate type (boiler or water heater): • BOILER: by pressing button • WATER HEATER: by pressing button to its maximum setting. to its maximum setting. 10.
AM Series Boilers and Water Heaters CHAPTER 4 – UNIT START-UP 4.7 Combustion Calibration Table 4-1 lists the correct CO2 and O2 ranges for a unit running at normal operating conditions at an altitude below 4500 feet (1371 meters). CO2 values outside of the ranges given in Table 41 may lead to malfunctioning of the unit and cause it to prematurely fail.
AM Series Boilers and Water Heaters CHAPTER 4 – UNIT START-UP Combustion Calibration (Cont.) 7. Set value of parameter 2010 to LOW. The Burner 1 (Master) will now run for 20 minutes at low fire input. 8. Wait 2 to 3 minutes for the CO2 to stabilize. 9. Compare the CO2 reading with the low fire range given in Table 11-1, making sure to use the range for the gas type in use.
AM Series Boilers and Water Heaters CHAPTER 4 – UNIT START-UP Combustion Calibration (Cont.) 18. Turn ON the main power to the unit. 19. Repeat Step 3 through Step 10 again. 20. Turn OFF the main power to the unit. 21. Disconnect plug “B” from connector “D” and connect it to connector “E” of the “Burner 4”, if present (See Figure 4-3). 22. Turn ON the main power to the unit. 23. Repeat Step 3 through Step 10 again. 24. Turn OFF the main power to the unit. 25.
AM Series Boilers and Water Heaters CHAPTER 5 – OPERATION CHAPTER 5: OPERATION 5.1 General Operation - Boilers This section applies only to the AM Series boilers. For Water Heaters, refer to Section 5.2. The boiler is pre-set with standard parameters. However, it is possible to make a number of changes to the parameters by means of using the “User Menu” (see Section 5.3) and the “Installer Menu” (see Section 5.4).
AM Series Boilers and Water Heaters CHAPTER 5 – OPERATION 5.1.1 Control Panel Display - Boilers During normal operation, the display remains off, except if the unit goes into Lockout, or has A Blocking error. Pressing any button will activate the display, which will stay on for 30 minutes from the time of the last button press. 5.1.2 Startup Procedure - Boilers This section applies only to AM Series boilers. For Water Heaters, refer to the next section 5.1. Boiler Startup Procedure 1.
AM Series Boilers and Water Heaters CHAPTER 5 – OPERATION 5.1.3 Boiler Summer Mode To disable the heating functions for a prolonged period, leaving only the domestic hot water function, press the key until the word OFF is displayed. Then press RESET button to save the change. Now the heating service is disabled, and is indicated by the disappearing from the display. icon 5.1.
AM Series Boilers and Water Heaters CHAPTER 5 – OPERATION 5.1.6 Heating System Temperature Adjustment - Boilers The boiler provides hot water to the heating system at the temperature set by adjusting buttons or as shown in Figure 5-1. To maximize the boilers’ performance, the heating temperature, should be set at a value that is just sufficient to maintain the desired temperature of the rooms. 5.1.
AM Series Boilers and Water Heaters CHAPTER 5 – OPERATION and 2024 (during spring season) to raise or lower the calculated temperature and match the desired room temperature. Figure 5-2: Outdoor Reset Settings Adjustment Graph Page 102 of 156 PRI - 07/14/14 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
AM Series Boilers and Water Heaters CHAPTER 5 – OPERATION 5.1.
AM Series Boilers and Water Heaters CHAPTER 5 – OPERATION 5.2 General Operation – Water Heaters This section applies only to the AM Series water heaters. For boilers, refer to section 5.1. The heater is pre-set with standard parameters. However, it is possible to make a number of changes or consult the parameters by means of using the User Menu (see Section 5.3) and the Installer Menu (see Section 5.4).
AM Series Boilers and Water Heaters CHAPTER 5 – OPERATION 5.2.1 Control Panel Display – Water Heaters During normal operation, the display remains off, except if the unit goes into Lockout, or has A Blocking error. Pressing any button will activate the display, which will stay on for 30 minutes from the time of the last button press. 5.2.2 Startup Procedure - Water Heaters This section applies only to the AM Series water heaters. For boilers, refer to the previous section.
AM Series Boilers and Water Heaters CHAPTER 5 – OPERATION 5.2.3 Adjusting the Storage Tank Temperature (Water Heaters) The storage tank temperature is adjusted by pressing keys and . When the keys are pressed, the display, item “N” in Figure 5-3, 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).
AM Series Boilers and Water Heaters CHAPTER 5 – OPERATION 5.3 User Menu – Boilers and Water Heaters Simultaneously pressing the RESET and buttons for 2 seconds will invoke the User Menu. When entering the User Menu, the 1000 series of parameters, as shown in Figure 5-4, are available for display, but cannot be altered. Parameters for “Burner 1” are applicable for that burner only.
AM Series Boilers and Water Heaters CHAPTER 5 – OPERATION 5.4 Installer Menu – Boilers and Water Heaters This menu of parameters is available to qualified technicians for the purpose of analyzing the function of, and making adjustments to, the unit. Parameters for “Burner 1” are applicable for that burner only. If you want to see the same parameters for the other burners you must connect the display to the burner you want to see per the instruction in Section 6.1.2.
AM Series Boilers and Water Heaters CHAPTER 5 – OPERATION Installer Menu Parameters - Boilers Figure 5-5: Boiler Installer Menu OMM-0100_0B GF-146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
AM Series Boilers and Water Heaters CHAPTER 5 – OPERATION 5.5 Diagnostics: Status Display During normal operation, the following diagnostic information may be shown in the display: Figure 5-6: Diagnostic Status Display – Boilers and Water Heaters 5.6 Diagnostics – Blocking (Loc) Errors Lockout errors will stop the unit from functioning until the error is resolved and the unit is reset. See Figure 7 for a chart of possible Lock Errors, with solutions.
AM Series Boilers and Water Heaters CHAPTER 5 – OPERATION Lockout (Loc) Error Messages WARNING! If the high temperature fuse is blown before it is replaced, it is mandatory to inform the manufacturer to prevent serious damage and a possible dangerous condition. WARNING! If the high temperature fuse is blown before it is replaced, it is mandatory to inform the manufacturer to prevent serious damage and a possible dangerous condition.
AM Series Boilers and Water Heaters CHAPTER 5 – OPERATION 5.7 Diagnostics – Blocking (Err) Errors Blocking errors are generated by a permanent fault. There is no way to unlock the unit other than to resolve the cause of the fault. To reset a lockout error, do the following: Resetting the Unit after a Lockout Error 1. When the boiler goes into lockout, the the burner icon(s) ( , , , or icon will show in the control panel display and ) associated with the lockout will blink. 2.
AM Series Boilers and Water Heaters CHAPTER 5 – OPERATION Blocking (Err) Error Messages Figure 5-8: Blocking (Err) Error Messages OMM-0100_0B GF-146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
AM Series Boilers and Water Heaters CHAPTER 5 – OPERATION 5.8 Blocked Flue Pressure Switch The AM Series units are equipped with a blocked flue pressure switch safety that shuts down the unit when the flue exhaust vent pipe is blocked. If this pressure switch shuts off the unit (Loc 25), do not attempt to place the boiler in operation but rather, contact a qualified service agency or technician able to reset the unit after checking for any potential dangerous situations. 5.
AM Series Boilers and Water Heaters CHAPTER 8 – SPARE PARTS CHAPTER 6: MAINTENANCE 6.1 Care and Maintenance – Boilers and Water Heaters This section must be brought to the attention of the user by the installer so that the user can make the necessary arrangements with a qualified service agency for the periodic care and maintenance of the boiler. Refer to Table 6-1 for a schedule of necessary maintenance procedures.
AM Series Boilers and Water Heaters CHAPTER 8 – SPARE PARTS 6.1.1 Checking for Gas Leaks • Inspect all gas piping and verify to be leak free. • Check for gas leaks: using soap solution, check for gas leaks from meter to appliance including all pipes and fittings and heater connection. Use liquid soap solution for all gas testing. 6.1.
AM Series Boilers and Water Heaters CHAPTER 8 – SPARE PARTS 6.1.8 Flame Signal Inspection • Start the unit and perform the combustion calibration procedure per section 4.7. • At high fire and low fire the flame signal (parameter 1008) should be within values given in Appendix A, under header “ionization current”. A lower flame signal may indicate a fouled or damaged flame sense electrode.
AM Series Boilers and Water Heaters CHAPTER 8 – SPARE PARTS 6.1.11 Pressure Gauge Inspection • Make sure the pressure reading on the heater pressure gauge (item “M” in Figures 5-1 or 5-3) does not exceed the maximum working pressure. Higher pressures may indicate a problem with the expansion tank. • Contact a qualified service technician if problem persists. 6.1.
AM Series Boilers and Water Heaters CHAPTER 8 – SPARE PARTS 6.1.15 Removing the Unit Covers In order to remove the unit covers, refer to Figure 6-1 and follow the steps below: Removing the Unit Covers 1. Lift up, by hand, cover “A”. 2. Remove screws “B”. 3. Pull back the upper side of cover “C” for 2 inches, then pull it up for one inch and remove it from the unit. 4. Pull back upper side of cover “E” for 2 inches, then pull it up for one inch and remove it from the unit. 5.
AM Series Boilers and Water Heaters CHAPTER 8 – SPARE PARTS 6.1.16 Cleaning the Burner and Primary Heat Exchanger (Flue/Gas Side) The burner and primary heat exchanger must be checked every year and cleaned if required.
AM Series Boilers and Water Heaters CHAPTER 8 – SPARE PARTS Cleaning the Burner and Primary Heat Exchanger (Cont.) 5. Rotate the air inlet silencer “B” (Figure 6-3) in the up direction. 6. Pull in the left direction “C” (Figure 6-3) the air inlet silencer and remove it from the fan. Figure 6-3: Removing the Air Inlet Silencer 7. Unscrew nut “H” (Figure 6-4). Take note of the gasket between nut “H” (Figure 6-4) and the gas valve and remove the electrical plug from the gas valve.
AM Series Boilers and Water Heaters CHAPTER 8 – SPARE PARTS Cleaning the Burner and Primary Heat Exchanger (Cont.) 9. Remove the gas valve from its position (see Figure 6-5). Note the O-ring “L” per Figure 6-5. Figure 6-5: Removing the Gas Valve 10. Unscrew the four nuts “B” in Figure 14-6; 11. Remove the entire fan and burner assembly, detail “C”, as shown in Figure 6-6 Figure 6-6: Removing the Fan and Burner Assembly Page 122 of 156 PRI - 07/14/14 AERCO International, Inc. • 100 Oritani Dr.
AM Series Boilers and Water Heaters CHAPTER 8 – SPARE PARTS Cleaning the Burner and Primary Heat Exchanger (Cont.) 12. Use a cylindrical brush with plastic bristles to clean the inside of the combustion chamber, detail “H” per Figure 6-6 13. Use a vacuum cleaner to remove any unburned residue from the combustion chamber “H” in Figure 6-6. 14. Clean the surfaces of the burner and around the electrodes using the vacuum cleaner.
AM Series Boilers and Water Heaters CHAPTER 8 – SPARE PARTS 6.1.17 Ignition and Flame Detection Sensor Electrode Positioning For the heater to work properly the electrodes must be positioned as listed below and shown in Figure 6-7: Ignition and Flame Detection Electrode Positioning To insure correct functioning of the burner, the distances listed below should be carefully verified by hand using calipers. • The distance between the ignition electrodes “A” and “B”, must be between 0.08 in (2 mm), and 0.
AM Series Boilers and Water Heaters CHAPTER 8 – SPARE PARTS 6.1.1 Air Filter Cleaning For the heater to work properly the air filter must be clean. A dirty air filter can cause a power input reduction 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 6.1.15 to gain access to the internal components. 2. Pull down with a rotating motion the air filter “B” as per Figure 6-8. 3.
AM Series Boilers and Water Heaters CHAPTER 8 – SPARE PARTS 6.1.1 Condensate Trap and Neutralizing Reservoir Maintenance The condensate trap and neutralizing reservoir must be checked every year and cleaned if required. Follow the steps below to properly inspect, refill or replace the condensate neutralizing reservoir and media: Monitor the level of the neutralization media in the reservoir periodically. The pH can be checked after the condensate has exited from pipe “A” of Figure 3-19.
AM Series Boilers and Water Heaters CHAPTER 8 – SPARE PARTS Condensate System Inspection and Maintenance (Cont.) 8. Replace the condensate cover and reinsert the condensate collection box assembly back into the unit. WARNING! The condensate collection box must be filled with water to prevent flue gas emissions from escaping during unit operation. Failure to comply with this requirement can result in dangerous levels of carbon monoxide. 9. Open the manual gas shutoff valve. 10.
AM Series Boilers and Water Heaters CHAPTER 8 – SPARE PARTS 6.1.2 Connection of the Control Panel Display to Each Burner Because AM Series boilers and water heaters are multi-burner units, the control panel display is always connected directly to “Burner 1 (Master)”. All parameters presented by the display are addressed only to “Burner 1 (Master)”. To observe or change, the same parameters for the other burners, you must change the display connection from “Burner 1 (Master)” to the burner desired.
AM Series Boilers and Water Heaters CHAPTER 8 – SPARE PARTS 6.1.3 Control Board Replacement The AM Series multi-burner units are configured to be driven by one control board (named Burner 1 (Master)). On this board are connected all external devices such as: room thermostat, outdoor sensor, pump commands, LWCO, and some internal safety devices such as blocked drain magnetic switch, flue blocked pressure switch, etc. If the Burner 1 control board fails, the complete unit stops functioning.
AM Series Boilers and Water Heaters CHAPTER 8 – SPARE PARTS Replacing the Burner 1 (Master) Control Board 9. Ensure that all connections that are now disconnected from the replacement board are secure from shorts or damage by electrically insulating each of the plugs. 10. Replace all covers. 11. Turn on electrical power to the unit. 12. Gain access to the Factory menu, per Appendix B, and set all parameters as shown in the column “Burner 1 (Master)”.
AM Series Boilers and Water Heaters CHAPTER 8 – SPARE PARTS 6.1.5 Water and Flue Temperature Sensor The boiler has a number of sensors that measure temperature. For proper function, the electrical resistance between the sensor wires must correspond with the values shown in Figure 6=14 for both boilers and water heaters. Figure 6-13: Water and Flue Temperature Sensor Curve 6.1.6 Outdoor Temperature Sensor (Boilers Only) An outdoor temperature sensor can be connected to the boiler (see Section 3.14.5).
AM Series Boilers and Water Heaters CHAPTER 8 – SPARE PARTS 6.2 Maintenance Kits Part Lists The annual and 24-month maintenance kits for the various models of AM units are shown in the table below. The basic kit part number is 58109, with the suffix of -01 through -06 appended to it to indicate the specific kit required.
AM Series Boilers and Water Heaters CHAPTER 6 – MAINTENANCE 6.2.1 Wiring Diagram - Boilers OMM-0100_0B GF-146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
AM Series Boilers and Water Heaters CHAPTER 6 – MAINTENANCE Page 134 of 156 PRI - 07/14/14 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
AM Series Boilers and Water Heaters CHAPTER 6 – MAINTENANCE 6.2.2 Wiring Diagram – Water Heaters OMM-0100_0B GF-146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
AM Series Boilers and Water Heaters CHAPTER 6 – MAINTENANCE Page 136 of 156 PRI - 07/14/14 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
AM Series Boilers and Water Heaters CHAPTER 7 – TECHNICAL DATA CHAPTER 7: TECHNICAL DATA OMM-0100_0B GF-146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
AM Series Boilers and Water Heaters CHAPTER 7 – TECHNICAL DATA (This page intentionally blank) Page 138 of 156 PRI - 07/14/14 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
AM Series Boilers and Water Heaters CHAPTER 8 – SPARE PARTS CHAPTER 8: SPARE PARTS 8.1 Spare Parts and Maintenance Kits 8.1.1 AM399/500 Spare Parts Drawings Figure 8-1a: AM399/500 General Assembly Part Drawing (1 of 2) OMM-0100_0B GF-146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
AM Series Boilers and Water Heaters CHAPTER 7 – TECHNICAL DATA Figure 8-1b: AM399/500 General Assembly Part drawing (2 of 2) Page 140 of 156 PRI - 07/14/14 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
AM Series Boilers and Water Heaters CHAPTER 8 – SPARE PARTS Figure 8-2: AM399/500 Burner/Fan Assembly Part Drawing OMM-0100_0B GF-146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
AM Series Boilers and Water Heaters CHAPTER 8 – SPARE PARTS 8.1.2 Models AM399/500 Spare Parts List Page 142 of 156 PRI - 07/14/14 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
AM Series Boilers and Water Heaters CHAPTER 8 – SPARE PARTS Models AM399/500 Spare Parts List (Cont.) OMM-0100_0B GF-146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
AM Series Boilers and Water Heaters CHAPTER 8 – SPARE PARTS Models AM399/500 Spare Parts List (Cont.) Page 144 of 156 PRI - 07/14/14 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
AM Series Boilers and Water Heaters CHAPTER 8 – SPARE PARTS 8.1.3 Models AM 750B / 1000B Spare Parts Drawings Figure 8-3a: AM750/1000 General Assembly Part Drawing (1 of 2) OMM-0100_0B GF-146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
AM Series Boilers and Water Heaters CHAPTER 8 – SPARE PARTS Figure 8-3b: AM750/1000 General Assembly Part Drawing (2 of 2) Page 146 of 156 PRI - 07/14/14 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
AM Series Boilers and Water Heaters CHAPTER 8 – SPARE PARTS Figure 8-5: AM 750/1000 Burner/Fan Assembly Part Drawing OMM-0100_0B GF-146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
AM Series Boilers and Water Heaters APPENDIX A – CONTROL PANEL OPERATIONAL FLOW CHART 8.1.4 Models AM750/1000 Spare Parts List Page 148 of 156 PRI - 07/14/14 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
AM Series Boilers and Water Heaters APPENDIX A – OPERATIONAL FLOW CHART Models AM750/1000 Spare Parts List (Cont.) OMM-0100_0B GF-146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
AM Series Boilers and Water Heaters APPENDIX A – CONTROL PANEL OPERATIONAL FLOW CHART Models AM 750B / 1000B Spare Parts List (Cont.) Page 150 of 156 PRI - 07/14/14 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
AM Series Boilers and Water Heaters APPENDIX A – OPERATIONAL FLOW CHART APPENDIX A: CONTROL PANEL OPERATIONAL FLOW CHART Figure A-1: Flow Chart of Control Panel Operation OMM-0100_0B GF-146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
AM Series Boilers and Water Heaters APPENDIX B – FACTORY MENU APPENDIX B: FACTORY MENU Inappropriate changes to parameters in the Factory Menu (See Tables B-1 and B-2) could result in a unit or system malfunction. For this reason, only a qualified technician who has in-depth knowledge of the unit should make any changes to the parameters in this menu. The parameters available allow the unit to be configured and set for proper operation.
AM Series Boilers and Water Heaters APPENDIX B – FACTORY MENU Appendix B: Factory Menu Figure B-1: Factory Menu – Boilers OMM-0100_0B GF-146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
AM Series Boilers and Water Heaters APPENDIX B – FACTORY MENU Appendix B: Factory Menu Figure B-2: Factory Menu – Water Heaters Page 154 of 156 PRI - 07/14/14 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
AM Series Boilers and Water Heaters STANDARD WARRANTY AM Series Gas Fired Hydronic Boilers and Water Heaters BOILER PRESSURE VESSEL/HEAT EXCHANGER: 7 YEARS NON-PRORATED The pressure vessel/heat exchanger shall carry a (7) seven year non-prorated warranty from shipment against any failure due to condensate corrosion, thermal stress, mechanical defects or workmanship. Operation of the boiler using contaminated air will void the warranty.
AM Series Boilers and Water Heaters INSTALLATION, OPERATION, AND MAINTWNANCE MANUAL Change Log: Date Description Changed By 04/10/2014 Rev-A: Release Curtis Harvey 07/14/2014 Rev-B: Revised Part Lists & Drawings, added Maintenance Kits Curtis Harvey © AERCO International, Inc., 2014 www.aerco.com Page 156 of 156 PRI - 07/14/14 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
